KR20230130643A - ice maker - Google Patents

Abstract

Commercial ice makers purge water from the sump through a passive drain valve instead of an active drain pump. Although ice makers use large freezing plates, they can still accommodate a manual drain valve within a standard enclosure footprint. The lower wall of the ice maker has a drain passage groove formed on the upper surface. The drain valve is supported on the lower wall and the drain tube is at least partially received in the drain passage groove. The drain valve may include a valve body having a valve seat and a movable valve member that opens and closes the valve passage through the valve seat. When the valve member is closed, the valve member radially overlaps the valve seat along the longitudinal axis.

Description

ice maker

Cross-reference to related applications

This application claims priority to U.S. Provisional Patent Application No. 17/147,965, filed January 13, 2021, which is hereby incorporated by reference in its entirety.

Field

The present disclosure relates to a type of ice maker configured to deposit ice in an ice bin below the ice maker.

A typical ice maker has a reservoir to hold a predetermined amount of water, some or all of which is frozen into ice by the ice maker. In ice makers that form cube ice, the water used for ice making is circulated through a water reservoir (also called a sump or trough) and a cooled freeze plate during ice making. Therefore, the circulated water is maintained at a relatively cold temperature around 0°C. In ice makers that form flake or nugget ice, the water reservoir (also called a float chamber) is filled with incoming water and is not cooled. During ice making, there is a steady flow of water supplied to the ice maker where ice is formed in the ice making chamber. In both cube ice makers and flake/nugget ice makers, when ice is not being made, the water remaining in the water reservoir is not cooled. Therefore, the temperature of the water may rise and the water may stagnate. To prevent stagnant water from contaminating the ice maker, both cube ice makers and flake/nugget ice makers include a mechanism for draining water from the reservoir when ice is not being made. For example, it is known to use discharge pumps to allow selective removal of water from a reservoir. It may also be desirable to periodically drain water from the water reservoir even while ice is being made to prevent the formation of high concentrations of scale or other contaminants in the water being used for ice making.

In one aspect, an ice maker includes a freezing plate that forms a plurality of molds through which the ice maker is configured to form ice. The freeze plate has a front portion forming an open front end of the mold, a rear portion forming an enclosed rear end of the mold, an upper portion and a lower portion spaced along the height, and first and second side portions spaced along the width. It has a side part. A distributor adjacent the upper portion of the freeze plate is configured to direct the water delivered through the distributor to flow downwardly along the front of the freeze plate and along the width of the freeze plate. The distributor includes a first end and a second end spaced apart along the width of the distributor. The lower wall extends widthwise from the first end to the second end and generally extends forward from the upstream end to the downstream end. The distributor is configured to direct the water delivered thereto to flow in a generally forward direction from the upstream end to the downstream end. A weir extends upward from the lower wall at a spaced location between the upstream and downstream ends. The weir is configured to allow water to flow across the weir as it flows along the bottom wall from the upstream end to the downstream end. The lower wall generally includes a slope immediately upstream of the embankment that slopes upward in a forward direction.

In another aspect, an ice maker includes a freezing plate that forms a plurality of molds through which the ice maker is configured to form ice. The freeze plate has a front portion forming an open front end of the mold, a rear portion forming an enclosed rear end of the mold, an upper portion and a lower portion spaced along the height, and first and second side portions spaced along the width. It has a side part. A distributor adjacent the upper portion of the freeze plate is configured to direct the water delivered through the distributor to flow downwardly along the front of the freeze plate and along the width of the freeze plate. The distributor includes a first end and a second end spaced apart along the width of the distributor. The lower wall extends widthwise from the first end to the second end and generally extends forward from the upstream end to the downstream end. The distributor is configured to direct the water delivered thereto to flow in a generally forward direction from the upstream end to the downstream end. The downstream end of the lower wall forms a downwardly curved surface tension curve. The downwardly curved surface tension curve is configured such that the surface tension causes the water delivered through the distributor to adhere to the curve and be guided downward by the curve towards the upper end of the freeze plate.

In another aspect, an ice maker includes a freezing plate that forms a plurality of molds through which the ice maker is configured to form ice. The freeze plate has a front portion forming an open front end of the mold, a rear portion forming an enclosed rear end of the mold, an upper portion and a lower portion spaced along the height, and first and second side portions spaced along the width. It has a side part. A distributor adjacent the upper portion of the freeze plate is configured to direct the water delivered through the distributor to flow downwardly along the front of the freeze plate and along the width of the freeze plate. The distributor includes a first end and a second end spaced apart along the width of the distributor. The lower wall extends widthwise from the first end to the second end and generally extends forward from the upstream end to the downstream end. The distributor is configured to direct the water delivered thereto to flow in a generally forward direction from the upstream end to the downstream end. The protruding front wall has a lower edge edge spaced above the lower wall adjacent its downstream end such that a flow restriction is formed between the lower wall and the protruding front wall. The flow restrictor includes a gap extending widthwise between the first and second ends of the distributor and is configured to limit the rate at which water flows through the flow restrictor to the downstream end of the lower wall.

In another aspect, an ice maker includes a freezing plate that forms a plurality of molds through which the ice maker is configured to form ice. The freeze plate has upper and lower portions spaced apart along the height, and first and second side portions spaced along the width. The distributor extends along the width of the freeze plate adjacent the upper portion of the freeze plate. The distributor is configured to direct the water delivered through the distributor to flow from the upper portion of the freeze plate to the lower portion along the width of the freeze plate. The distributor includes a first distributor part and a second distributor part. The second distributor part is configured to be releasably coupled to the first distributor part without a separate fastener to form a distributor.

In another aspect, an ice maker includes a freezing plate that forms a plurality of molds through which the ice maker is configured to form ice. The freeze plate has upper and lower portions spaced apart along the height, and first and second side portions spaced along the width. The distributor adjacent the upper portion of the freeze plate has a width extending along the width of the freeze plate. The distributor has an inlet and an outlet and forms a distributor flow path extending from the inlet to the outlet. The distributor is configured to guide the water delivered through the distributor along the distributor flow path and discharge the water from the outlet so that the water flows from the upper portion of the freeze plate to the lower portion along the width of the freeze plate. The distributor includes a first distributor part and a second distributor part. The second distributor part is releasably coupled to the first distributor part to form a distributor. The first distributor part includes a bottom wall defining a groove extending widthwise, and the second distributor part includes a generally vertical berm defining a plurality of spaced openings along the width of the distributor. The weir has a free lower edge edge received in a groove such that water flowing along the distributor flow path is arrested from flowing through the interface between the lower edge edge of the weir and the lower wall and is directed to flow across the weir through a plurality of openings. have

In another aspect, an ice maker includes an evaporator assembly including a freezing plate forming a plurality of molds in which the evaporator assembly is configured to form pieces of ice. The freeze plate has a front portion that forms the open front end of the mold and a rear portion that extends along the closed rear end of the mold. The evaporator housing has a rear portion and defines an enclosed space between the rear portion of the freeze plate and the rear portion of the evaporator housing. The refrigerant piping is accommodated within the enclosed space. The insulation material substantially fills the enclosed space around the refrigerant piping. The water system is configured to supply water to the freezing plate such that the water forms into ice within the mold. The evaporator housing includes a distributor component formed from a single, monolithic material component. The distributor part is in direct contact with the insulation and has a bottom wall. The water system is configured to direct the water to flow along the bottom wall when it is supplied to the freezing plate.

In another aspect, an ice maker includes an evaporator assembly including a freezing plate forming a plurality of molds in which the evaporator assembly is configured to form pieces of ice. The freeze plate has a front portion that forms the open front end of the mold, a rear portion that extends along the closed rear end of the mold, an upper wall that is formed from a single monolithic material piece and that forms the upper end of at least one of the molds, and It has at least one stud coupled to the top wall and extending upwardly therefrom. The distributor is configured to distribute the water delivered through the distributor onto the freezing plate such that the water forms into ice in the mold. The distributor includes a distributor component formed from a single, monolithic material component. The distributor part includes a bottom wall that forms part of a flow path through which the distributor directs water to flow through the distributor. A nut is tightened on each stud for the distributor part to mount the distributor directly on the freeze plate.

In another aspect, a distributor for receiving water delivered through the distributor and directing the water to flow along the freeze plate of the ice maker such that the water forms as ice on the freeze plate includes a rear wall adjacent the upstream end of the distributor, the rear wall a lower wall extending forward from the distributor to a front end adjacent the downstream end of the distributor, and a tube projecting rearwardly from the rear wall. The rear wall has an opening immediately above the lower wall through which the tube is in fluid communication with the distributor. The lower wall includes a rear section that slopes downward to the rear wall and a front section that slopes downward to the front end.

In another aspect, an ice maker includes an enclosure. A freezing plate is housed within the enclosure. The freeze plate includes a rear wall and a front portion opposite the rear wall. The freeze plate further includes a peripheral wall extending anteriorly from the posterior wall. The peripheral wall includes an upper wall portion, a lower wall portion, a first side wall portion, and a second side wall portion. The first side wall portion and the second side wall portion define the width of the freezing plate. The freezing plate includes a plurality of height direction divider plates extending from a lower end connected to the lower wall to an upper end connected to the upper wall and a plurality of width direction divider plates extending from a first end connected to the first side wall to a second end connected to the second side wall. It further includes a divider plate. The height direction divider plate and the width direction divider plate are connected to each other to form a plurality of ice molds inside the peripheral wall. Each widthwise divider plate forms a plurality of molds directly above the divider plate and a plurality of molds directly below the divider plate. Each transverse divider plate is tilted downward and forward away from the rear wall of the freeze plate such that the included angle between the top surface of each transverse divider plate and the rear wall is greater than 90° and less than 180°. The distributor is configured to direct the water delivered through the distributor to flow downwardly along the freeze plate along the width of the freeze plate. The freeze plate is supported within the enclosure such that the rear wall of the freeze plate slopes forward.

In another aspect, an ice maker includes an enclosure having a lower portion. The evaporator assembly is supported within the enclosure. The evaporator assembly includes an evaporator and a freeze plate forming a plurality of molds in which the evaporator assembly is configured to form a piece of ice. The evaporator assembly has a lower portion. The distributor is configured to distribute water delivered through the distributor onto the freeze plate such that the water forms into ice on the freeze plate. A sump is supported within the enclosure below the freeze plate and is configured to collect water flowing from the bottom of the freeze plate. The pump is configured to pump water in the sump through the distributor. A drain valve is supported within the enclosure. The drain valve is configured to selectively open and drain all water from the sump by gravity. The bottom of the evaporator assembly is spaced from the bottom of the enclosure by less than 12 inches in height.

In another aspect, an ice maker includes an enclosure having a bottom, a top, and a height extending from the bottom to the top. The evaporator assembly is supported within the enclosure. The evaporator assembly includes an evaporator and a freeze plate forming a plurality of molds in which the evaporator assembly is configured to form a piece of ice. The evaporator assembly has a lower portion. The freeze plate has a top and the evaporator assembly has a height extending from the bottom of the evaporator assembly to the top of the freeze plate. The dispenser is supported within an enclosure adjacent to the top of the freeze plate. The distributor is configured to distribute the water delivered through the distributor onto the freezing plate such that the water forms into ice in the mold. A sump is supported within the enclosure below the freeze plate and is configured to collect water flowing from the bottom of the freeze plate. The pump is configured to pump water in the sump through the distributor. A drain valve is supported within the enclosure. The drain valve is configured to selectively open and drain all water from the sump by gravity. The height of the enclosure is less than 24 inches and the height extending from the bottom of the evaporator assembly to the top of the freeze plate is more than 10 inches.

In another aspect, the ice maker includes a bottom wall. The lower wall has a drainage passage groove formed on the upper surface of the lower wall. The ice forming device is supported on the bottom wall. The water reservoir holds water used by the ice forming device. The water reservoir is supported on the bottom wall. A drain valve is supported on the wall. The drain valve is configured to selectively open and drain all water from the water reservoir by gravity. A drain tube is supported on the lower wall and is at least partially received within the drain passage groove.

In another aspect, an ice maker for forming ice includes an ice forming device and a cooling system including a water system for supplying water to the ice forming device. The water system includes a water reservoir configured to retain water to form ice. The drain passage is fluidly coupled to the water reservoir so that water in the water reservoir can drain through the drain passage. The drain passage has an upstream end and a downstream end. The drain valve selectively opens and closes the drain passage. The drain valve includes a valve body that forms a valve passage fluidly coupled between an upstream end and a downstream end of the drain passage. The valve body includes an annular valve seat extending longitudinally along an axis and oriented radially inwardly with respect to the axis. The drain valve has an open position in which the valve member is positioned relative to the valve body to allow water to flow through the valve passage from the upstream end to the downstream end of the drain passage, and an open position in which the valve member is positioned relative to the valve body to allow water to flow through the valve passage from the upstream end to the downstream end of the drain passage. and a valve member movable relative to the valve body between a closed position engaged with the valve body to block flow therethrough. The valve member includes an annular sealing surface extending longitudinally along the axis. The annular sealing surface is configured to radially overlap and sealingly engage the valve seat along its axis when the valve member is in the closed position.

Other aspects will become partly apparent and partly pointed out below.

1 is a schematic diagram of an ice maker.
Figure 2 is a perspective view of an ice maker supported on an ice bucket.
Figure 3 is a perspective view of the sub-assembly of the ice maker including the support, evaporator assembly, sump, mounting plate and sensor fitting.
Figure 4 is an exploded perspective view of the sub-assembly of Figure 3;
Figure 5 is a side elevation view of the sub-assembly of Figure 3;
Figure 6 is a perspective view of the freezing plate of an ice maker.
Figure 7 is an exploded perspective view of the freezing plate.
Figure 8 is a vertical cross-sectional view of the freezing plate.
Figure 9 is a perspective view of the evaporator assembly.
Figure 10 is a side elevation view of the evaporator assembly.
Figure 11 is a top plan view of the evaporator assembly.
Figure 12 is an exploded perspective view of the evaporator assembly.
Figure 13 is a rear elevation view of the evaporator assembly with the rear wall removed to expose the serpentine evaporator piping.
Figure 14 is a cross-sectional view of the evaporator assembly taken in the plane of line 14-14 of Figure 11.
Figure 15 is a perspective view of the evaporator assembly showing the upper distributor part removed and the lower distributor part/upper evaporator housing part and their associated components disassembled away from the remainder of the evaporator assembly.
Figure 16 is an enlarged vertical cross-sectional view of the components of the evaporator assembly shown in Figure 15 taken in a plane passing through the studs of the freeze plate.
Figure 17 is a vertical cross-sectional view of the evaporator assembly mounted on a support.
Figure 18 is a perspective view of a distributor of an evaporator assembly.
Figure 19 is an exploded perspective view of the distributor.
Figure 20 is a vertical cross-sectional view of the distributor.
FIG. 20A is an enlarged view of a portion of FIG. 20.
Figure 21 is a top perspective view of the lower distributor component.
Figure 22 is a bottom perspective view of the lower distributor component.
Figure 23 is a vertical cross-section similar to Figure 15 except that the plane of the cross-section passes through the center of the inlet tube of the lower distributor part.
Figure 24 is an enlarged perspective view of the end portion of the lower distributor part.
Figure 25 is a perspective view of the upper distributor component.
Figure 26 is a bottom plan view of the upper distributor component.
Figure 27 is a rear elevation view of the upper distributor component.
Figure 28 is an enlarged perspective view of the end portion of the upper distributor part.
Figure 29 is a perspective view of the evaporator assembly with the upper distributor component spaced in front of the lower distributor component.
30 is housed within a schematically illustrated ice maker enclosure, the plane of the cross-section being just inside the right side wall portion of the vertical side wall of the support as shown in FIG. 3, with the upper distributor part removed outside of the enclosure. This is a vertical cross-sectional view of the subassembly of FIG. 3 shown in the indicated position.
Figure 31 is an enlarged horizontal cross-sectional view of an end portion of the distributor viewed downward in a plane passing through an elongate tongue of the lower distributor part received in an elongated groove of the lower distributor part.
Figure 32 is a vertical cross-sectional view of the distributor taken in a plane passing through the divided weir.
33 is a schematic diagram of the ice level detection system of an ice maker.
Figure 34 is a perspective view of an ice maker sub-assembly including a single piece support and a time-of-flight sensor.
Figure 35 is a top plan view of the sub-assembly of Figure 34;
Figure 36 is an exploded perspective view of the sub-assembly of Figure 34.
Figure 37 is a cross-sectional view taken in the plane of line 37-37 in Figure 35.
Figure 38 is an exploded perspective view of the time-of-flight sensor.
Figure 39 is a vertical cross-sectional view through a sub-assembly of the ice maker including the ice maker's cabinet, evaporator assembly, sump and drain passage.
Figure 39A is a vertical cross-sectional view similar to Figure 39 of another embodiment of the ice maker.
Figure 40 is a perspective view of a sub-assembly of the ice maker of Figures 1-39 including a support, drain passage and sump.
Figure 41 is a top view of the sub-assembly of Figure 40;
Figure 42 is a cross-sectional view taken in the plane of line 42-42 in Figure 41.
Figure 43 is a cross-sectional view of the drain valve of an ice maker, showing the drain valve in the open position.
Figure 44 is a cross-sectional view of a drain valve similar to Figure 43, except that the drain valve is shown in the closed position.
Figure 45 is a perspective view of the support portion.
Figure 46 is an enlarged view of the portion of Figure 39.
Figure 47 is an enlarged cross-sectional view similar to Figure 46 of the support portion of the ice maker, only with the drain passage removed therefrom.
Corresponding reference numbers indicate corresponding parts throughout the drawings.

1, one embodiment of an ice maker is designated generally by reference numeral 10. The present disclosure provides example features of ice maker 10 that can be used individually or in combination to improve ice making uniformity, ice harvesting performance, energy efficiency, assembly precision, and/or accessibility for repair or maintenance. Explain in detail. One aspect of the disclosure relates to an evaporator assembly including an evaporator, a freeze plate, and a water distributor. As described in more detail below, in one or more embodiments, the parts of the evaporator assembly are integrated together into a single unit. In certain embodiments, the water distributor includes configurations of water distribution features that provide uniform water flow along the width of the freeze plate. In an exemplary embodiment, the water dispenser is configured to provide immediate access to the interior of the dispenser for repair or maintenance. In one or more embodiments, the evaporator assembly is configured to mount the freeze plate within the ice maker in an orientation that reduces the time required to passively harvest ice using gravity and heat. Other aspects and features of ice maker 10 will also be described below. Although this disclosure describes an ice maker that combines a number of different features, it will be understood that other ice makers may use any one or more of the features disclosed herein without departing from the scope of the disclosure. .

The present disclosure begins with an overview of the ice maker 10 before providing a detailed description of an exemplary embodiment of an evaporator assembly.

I. Cooling system

1, the cooling system of the ice maker 10 includes a compressor 12, a heat dissipation heat exchanger 14, a refrigerant expansion device 18 to lower the temperature and pressure of the refrigerant, and an evaporator assembly 20 (extensive It includes an ice forming device), and a hot gas valve 24. As shown, heat dissipation heat exchanger 14 may include a condenser for condensing compressed refrigerant vapor discharged from compressor 12. In other embodiments, for example, in cooling systems utilizing carbon dioxide refrigerants where the heat release is supercritical, it is possible for a heat release heat exchanger to remove heat from the refrigerant without condensing the refrigerant. The illustrated evaporator assembly 20 integrates the evaporator 21 (e.g., serpentine refrigerant tubing), freeze plate 22, and water distributor 25 into one unit, as described in more detail below. . In one or more embodiments, a hot gas valve is provided to direct warm refrigerant from compressor 15 directly to evaporator 21 to remove or harvest ice cubes from freeze plate 22 when the ice reaches a desired thickness. 24) is used.

Refrigerant expansion device 18 may be of any suitable type, including capillary tubes, thermostatic expansion valves, or electronic expansion valves. In certain embodiments, when the refrigerant expansion device 18 is a thermostatic expansion valve or an electronic expansion valve, the ice maker 10 is disposed at the outlet of the evaporator piping 21 to control the refrigerant expansion device 18. It may also include a temperature sensor 26. In another embodiment, when the refrigerant expansion device 18 is an electronic expansion valve, the ice maker 10 may be connected to the evaporator piping 21 to control the refrigerant expansion device 19, as is known in the art. It may also include a pressure sensor (not shown) disposed at the outlet. In certain embodiments that utilize a gaseous cooling medium (e.g., air) to provide condenser cooling, a condenser fan 15 may be positioned to blow the gaseous cooling medium across the condenser 14. . One form of refrigerant circulates through these components via refrigerant lines 28a, 28b, 28c, and 28d.

II. water system

1 , the water system of the illustrated ice maker 10 includes a water reservoir or sump assembly (70), a water pump (62), a water supply line (63), and a water level sensor (64). 60). The water system of the ice maker 10 further includes a water supply line (not shown) and a water inlet valve (not shown) for charging the sump 70 with water from a water source (not shown). . The illustrated water system includes a drain passage 78 (broadly, a discharge line) and a drain valve 512 disposed thereon (e.g., a purge valve, drain valve (see below) for draining water from the sump 70. described)). A sump 70 may be positioned below the freeze plate 22 to capture water leaving the freeze plate so that the water may be recirculated by the water pump 62. A water supply line 63 fluidly connects the water pump 62 to the water distributor 25. During the de-icing cycle, pump 62 is configured to pump water through water supply line 63 and through distributor 25. As described in more detail below, distributor 25 includes water distribution features that distribute water delivered through the distributor evenly across the front of freeze plate 22. In an exemplary embodiment, the water supply line 63 is arranged in such a way that when ice is not being made, at least a portion of the water can drain from the distributor through the water supply line and into the sump.

In an exemplary embodiment, water level sensor 64 includes a remote air pressure sensor 66. However, it will be appreciated that any type of water level sensor may be used in the ice maker 10, including but not limited to float sensors, acoustic sensors, or electrical continuity sensors. The illustrated water level sensor 64 includes a fitting 68 configured to couple the sensor to the sump 70 (see also Figure 4). Fitting 68 is fluidly connected to pneumatic tube 69. Pneumatic tube 69 provides fluid communication between fitting 68 and air pressure sensor 66. The water in the sump 70 traps air in the fitting 68 and compresses the air by an amount that varies depending on the level of water in the sump. Accordingly, the pressure detected by air pressure sensor 66 can be used to determine the water level in sump 70. Additional details of an exemplary embodiment of a water level sensor including a remote air pressure sensor are described in US Patent Application Publication No. 2016/0054043, which is hereby incorporated by reference in its entirety.

In the illustrated embodiment, the sump assembly 60 further includes a mounting plate 72 configured to operably support both the water pump 62 and the water level sensor fitting 68 on the sump 70 . An exemplary embodiment of mounting plate 72 is shown in FIG. 4 . Mounting plate 72, as described in pending U.S. patent application Ser. No. 16/746,828, filed January 18, 2020, entitled ICE MAKER, which is incorporated herein by reference in its entirety. may form an integral sensor mount 74 for operatively mounting a sensor fitting 68 on the sump 70 in a sensing position where the water level sensor 64 operates to detect the amount of water in the sump. The mounting plate 72 may also form a pump mount 76 for mounting a water pump 62 on the sump 70 for pumping water from the sump through the water supply line 63 and distributor 25. there is. Each of sensor mount 74 and pump mount 76 may include locking features that facilitate releasably connecting each of water level sensor 64 and water pump 62 to sump 70. .

III. controller

Referring back to FIG. 1 , ice maker 10 may also include a controller 80 . Controller 80 may, in one or more embodiments, be located remotely from de-icing device 20 and sump 70 or may include one or more embedded processors. Controller 80 may include a processor 82 to control the operation of ice maker 10, including various components of the cooling system and water system. Processor 82 of controller 80 may include non-transitory processor-readable media that stores code representing instructions that cause the processor to perform a process. Processor 82 may be, for example, a commercially available microprocessor, an application specific integrated circuit (ASIC), or a combination of ASICs designed to accomplish one or more specific functions or enable one or more specific devices or applications. In certain embodiments, controller 80 may be an analog or digital circuit, or a combination of multiple circuits. Controller 80 may also include one or more memory components (not shown) for storing data in a form retrievable by the controller. Controller 80 may store data in or retrieve data from one or more memory elements.

In various embodiments, controller 80 may also include input/output (I/O) components (not shown) to communicate with and/or control various components of ice maker 10. In certain embodiments, for example, controller 80 may include water level sensor 64, a harvest sensor (not shown) to determine when ice is to be harvested, an electrical power source (not shown), ice One or more instructions, signals, messages, commands from various sensors and/or switches, including, but not limited to, level sensors (in § XI, described below) and/or pressure transducers, temperature sensors, acoustic sensors, etc. , may receive input such as data and/or any other information. In various embodiments, for example, based on these inputs, controller 80 may, for example, transmit one or more instructions, signals, messages, commands, data and/or any other information to these components, thereby controlling the compressor ( 12), condenser fan 15, refrigerant expansion device 18, hot gas valve 24, water inlet valve (not shown), drain valve 510 and/or water pump 62. It might be possible.

IV. Enclosure/Ice Bin

Referring to FIG. 2 , one or more components of ice maker 10 may be stored inside an enclosure 29 of ice maker 10 that defines an interior space. For example, some or all of the cooling system and water system of the ice maker 10 described above may be housed within the interior space of the enclosure 29 . In the illustrated embodiment, enclosure 29 is mounted on top of ice storage bin assembly 30. The ice storage bin assembly 30 includes an ice storage bin 31 having an open top (not shown) through which ice produced by the ice maker 10 falls. The ice is then stored within cavity 36 until retrieval. The ice storage bin 31 further includes an opening 38 providing access to the cavity 36 and the ice stored therein. Cavity 36, ice hole (not shown) and opening 38 are located in the left wall 33a, right wall 33b, front wall 34, rear wall 35 and bottom wall (not shown). ) is formed by. The walls of the ice storage bin 31 may be open or closed, made of, but not limited to, fiberglass insulation or, for example, polystyrene or polyurethane, to retard the melting of ice stored within the ice storage bin 31. It may also be insulated with a variety of insulating materials, including cellular foam. Door 40 may be opened to provide access to cavity 36.

The illustrated enclosure 29 is comprised of a cabinet 50 (broadly a fixed enclosure portion) and a door 52 (broadly a movable or removable enclosure portion). 2, the door 40 of the ice storage bin assembly 30 is raised to partially obscure the ice maker door 52. Door 52 is moveable relative to cabinet 50 (e.g., on hinges) to selectively provide access to the interior space of ice maker 10. Accordingly, a technician may open door 52 to access internal components of ice maker 10 through a doorway (not shown; broadly referred to as an access opening) as required for repair or maintenance. . In one or more other embodiments, the door may be opened in other ways, such as by removing the door assembly from the cabinet.

Additional details about exemplary embodiments of enclosures within the scope of the present disclosure are given in the Invention Title, filed January 18, 2020, assigned to the assignee of the present application, which is hereby incorporated by reference in its entirety. It is described in U.S. patent application Ser. No. 16/746,835, entitled Ice Maker, Ice Dispensing Assembly and Method of Deploying Ice Maker.

V. Internal support

3-5, the illustrated ice maker 10 includes a one-piece support 110 configured to support multiple components of the ice maker within an enclosure 29. For example, the illustrated support 110 is configured to support the sump 70, mounting plate 72, and evaporator assembly 20 at very precise positions to limit the possibility of misplacement of these components. The inventors have recognized that an ice maker control scheme using water level as a control input requires precise placement of a water level sensor within the sump. If the location of the water level sensor deviates by even a small amount (e.g., millimeters or less) from its designated location, the control scheme may become confused. The inventors have also recognized that aggregate dimensional tolerances of parts in conventional assemblies for mounting internal ice maker components can cause misplacement. Additionally, the inventors have recognized that precise positioning of the evaporator assembly within an ice maker can improve gravity ice making and ice harvesting performance.

In the illustrated embodiment, support 110 includes a base 112 and a vertical support wall 114. The illustrated vertical support wall includes a first side wall portion 116, a second side wall portion 118, and a rear wall portion 120 extending widthwise between the first and second side wall portions. A large opening 122 extends widthwise between the front end edges of the side wall portions 116 and 118. When the ice maker 10 is fully assembled, this opening 122 is positioned at the front of the enclosure 29 to allow technicians to access the components supported on the vertical wall through the opening when the door 52 is opened. It is located adjacent to (268) (Figure 30). A drop opening 123 (FIG. 35) is formed in the base 112 of the support and extends widthwise between the side wall portions 116 and 118 and forward from the rear wall portion 120. Ice harvested from the ice maker 10 may fall through the drop opening 120 into an ice bucket 30 located below the ice maker.

Each side wall portion 116, 118 includes an integral evaporator mount 124 (broadly a freeze plate mount). Evaporator mount 124 is configured to support evaporator assembly 20 in an operating position of ice maker 10. Each side wall portion 116, 118 further includes an integrated mounting plate mount 126 spaced below the evaporator mount 124. Mounting plate mount 126 is configured to support mounting plate 72 such that the mounting plate can mount water level sensor fitting 68 and pump 62 in an operating position of ice maker 10. An integrated sump mount 128 for attaching the sump 70 to the ice maker is spaced below the mounting plate mount 126 of each side wall portion 116, 118. 3-5, only the mounting portions 124, 126, 128 formed by the right wall portion 116 are shown, but it will be understood that the left wall portion 118 has substantially the same mirror symmetrical mounting portion in the illustrated embodiment. You will be able to.

At least one of the side wall portions 116, 118 forming the mounting portions 124, 126, 128 is formed from a single monolithic material piece. For example, in one or more embodiments, the entire vertical support wall 114 is formed from a single monolithic material piece. In the illustrated embodiment, the entire support 110, including the base 112 and the vertical support walls 114, is formed from a single, monolithic material piece. In one or more embodiments, support 110 is a single molded part. In the illustrated embodiment, monolithic support 110 is formed by compression molding. Forming the support 110 from a single part eliminates the stacking of tolerances that occur in multi-part support assemblies, thereby increasing the accuracy of placement of parts mounted on the support.

The evaporator mount 124 is configured to mount the evaporator assembly 20 on a vertical support wall 114 within the enclosure 29 such that the freeze plate 22 is tilted forward. To achieve this, in the illustrated embodiment each evaporator mount 124 includes a lower connection point 130 and an upper connection point 132 spaced forward from the lower connection point. As shown in Figure 5, the connection points 130, 132 are virtual lines oriented at an angle α inclined forward with respect to the plane BP of the rear wall portion 120 of the vertical support wall 114. It is spaced along (IL1). In use, the ice maker 10 is positioned such that the plane BP of the rear wall portion 120 is substantially parallel to the vertical axis VA. In this way, the virtual line IL1 is inclined forward with respect to the vertical axis VA at an angle α.

In the illustrated embodiment, each of the upper and lower connection points 130, 132 includes a screw hole. In use, the evaporator 20 is positioned between side wall portions 116 and 118 and a screw (not shown) is placed through each screw hole into a corresponding preformed screw hole associated with the evaporator assembly 20. As will be explained below, the preformed evaporator screw holes are arranged so that the freeze plate 22 is tilted forward when they are aligned with the evaporator mounting screw holes 130, 132. It will be appreciated that the integrated evaporator mount may include other types of connection points in addition to screw holes in one or more embodiments. For example, it is expressly contemplated that one or both of the screw holes 130, 132 may be replaced with an integrally formed stud or other structure that can be used to registerly attach the freeze plate to the support at an appropriate location.

Each mounting plate mount 126 includes a pair of generally horizontally spaced tapered threaded holes 134 (broadly referred to as connection points). Similarly, each sump mounting portion 128 includes a pair of generally horizontally spaced mounting holes 136 (broadly, connection points). Again, holes 134, 136 in mounting plate mount 126 and sump mount 128 may be replaced with other types of integral connection points in one or more embodiments.

As shown in FIG. 4 , in one or more embodiments, sump 70 is generally sized and arranged to be received within the space between side wall portions 116 and 118 of vertical support wall 114. Each of the first and second ends of the sump 70 spaced apart in the width direction includes a pair of protrusions 138 at spaced apart locations. A protrusion 138 on each end of the sump 70 is configured to be received within a pair of mounting holes 136 formed by each of the sump mounting portions 128. Protrusions 138 are received within mounting holes 136, thereby positioning sump 70 at precisely designated positions along the height of support 110. Additionally, screws (not shown) are inserted through each mounting hole 136 and screwed into each projection 138 to fasten the sump 70 onto the support 110 at a designated location.

Like the sump 70, the illustrated mounting plate 72 includes a first end and a second end that are spaced apart in the width direction. Each end of the mounting plate 114 defines a pair of preformed screw holes configured to align with the screw holes 134 of the corresponding mounting portion 126 of the support portion 110. Screws (broadly, mechanical fasteners; not shown) pass through screw holes 134 and are threaded into pre-formed holes in mounting plate 72 to position supports 110 at precisely specified locations along the height of the support. ) Connect the mounting plate to the In one or more embodiments, countersunk head screws (e.g., screws with tapered heads) are used to connect mounting plate 72 to support 110. The countersunk screw is self-centered within the tapered screw hole 134.

A one-piece support 110 with integral mounting portions 124, 126, 128 is provided to ensure that the evaporator assembly 20, mounting plate 72, and sump 70 are supported within the ice maker 10 in designated positions. You can see that it can be used. The support 110 may thereby position the freeze plate 22 to optimally balance desired performance characteristics, such as water distribution during deicing and ease/speed of ice harvesting. Additionally, the support 110 is positioned relative to the sump 70 such that a pressure sensor fitting 68 mounted within the sensor mount 74 is precisely positioned relative to the sump to accurately detect the water level using the sensor 64. Mounting plate 72 can be positioned. Likewise, the support portion 110 supports the sump 70 such that the pump 62 is precisely positioned to pump water from the sump 70 through the ice maker 10 when the pump is mounted on the pump mount 76. Position the mounting plate 72 relative to .

VI. freeze plate

6-8, an exemplary embodiment of the freeze plate 22 will now be described, before referring to other components of the evaporator assembly 20 that attach the freeze plate to the support 110. Freezing plate 22 forms a plurality of molds 150 through which ice maker 10 is configured to form ice. Freeze plate 22 has a front portion forming the open front end of mold 150, a rear portion forming an enclosed rear end of the mold, an upper portion and a lower portion spaced apart along a height HF, and a width It has a right side part (broadly, a first side part) and a left side part (broadly, a second side part) spaced along WF).

Throughout this disclosure, when the terms “front,” “back,” “back,” “front,” “back,” and the like are used in reference to any portion of the evaporator assembly 20, the freeze plate mold 150 The relative positions of the open front end and the enclosed rear end of provide a spatial frame of reference. For example, the front portion of the freeze plate 22 forming the open front end of the mold 150 is spaced from the rear of the freeze plate in the forward direction (FD) (FIG. 8) and along the enclosed rear end of the mold. The extending rear portion of the freeze plate is spaced apart from the front portion of the freeze plate in the posterior direction (RD).

In the illustrated embodiment, the freeze plate 22 includes a pan 152 having a rear wall 154 forming the rear portion of the freeze plate. Suitably, pan 152 is formed from a thermally conductive material, such as copper, and has one or more surfaces optionally coated with a food safe material. As is known in the art, evaporator tubing 21 is thermally coupled to the rear wall 154 of freeze plate 22 to cool the freeze plate during the de-icing cycle and to warm the freeze plate during the harvest cycle.

The fan 152 further includes a peripheral wall 156 extending forward from the rear wall 154. The peripheral wall 156 includes an upper wall portion, a lower wall portion, a right wall portion (broadly, a first side wall portion), and a left wall portion (broadly, a second side wall portion). The side wall portions of the peripheral wall 156 form opposite sides of the freeze plate 22, and the upper and lower wall portions of the peripheral wall form the upper and lower ends of the freeze plate. Peripheral wall 156 may be formed from one or more separate components joined to rear wall 154 or fan 152, or the entire fan may be formed from a single, monolithic material component in one or more embodiments. . Suitably, the peripheral wall 156 is sealed to the rear wall 154 such that water flowing under the freeze plate 22 does not leak through the rear portion of the freeze plate.

A plurality of height and width direction divider plates 160 and 162 are fixed to the pan to form a grid of the ice cube mold 150. In the exemplary embodiment, each height divider plate 160 and each width divider plate 162 are formed from a single monolithic material piece. Each height splitter plate 160 has a right side surface (broadly a first side surface) and a left side surface oriented parallel to the right side surface (broadly a second side surface). Each width divider plate 162 has a lower surface and an upper surface oriented parallel to the lower surface. The height divider plate 162 extends from a lower end that is sealingly connected to the lower wall of the peripheral wall 156 to an upper end that is sealingly connected to the upper wall of the peripheral wall. The plurality of transverse divider plates 160 similarly extend from a first end sealingly connected to the right wall portion of the peripheral wall 156 to a second end sealingly connected to the left wall portion of the peripheral wall.

Generally, the height divider plate 160 and the width divider plate 162 are interconnected in this way to form a plurality of ice molds 150 within the peripheral wall 156. For example, in the illustrated embodiment, each height divider plate 160 has a plurality of vertically spaced forward opening slots 164; Each transverse diver plate has a plurality of horizontally spaced rear opening slots 166; The height and width divider plates are interlocked in slots 164, 166 to form a grid. Suitably, each transverse divider plate 162 has a plurality of molds 150 (e.g., at least three molds) directly above the divider plate and a plurality of molds (e.g., at least three molds) directly below the divider plate. form a mold). Each height-directed divider plate 160 likewise has a plurality of molds 150 (e.g., at least three molds) directly on one side of the divider plate and a plurality of molds (e.g., at least three molds) directly on the opposite side of the divider plate. Form at least 3 molds).

Each divider plate 160, 162 has a front edge and a back edge. The rear edge may suitably be sealingly coupled to the rear wall 154 of the freeze plate pan 152. When the freeze plate 22 is assembled, the front edges of some or all of the divider plates 160, 162 (e.g., at least the transverse divider plates) are substantially in the front plane FP (FP) of the freeze plate 22. Figure 8) It is placed on the table. In one or more embodiments, anterior plane FP is parallel to posterior wall 154.

The plurality of ice molds 150 formed on the freezing plate 22 are internal ice molds having a perimeter substantially entirely formed by the height and width direction divider plates 160, 162. The other mold 150 is a perimeter mold with its perimeter defined by the perimeter wall 156 of the freeze plate pan 152. Each internal ice mold 150 has an upper end formed substantially entirely by the lower surface of one of the transverse divider plates 162 and a lower end formed substantially entirely by the upper surface of an adjacent one of the transverse divider plates 162 . Additionally, each inner mold 150 has a left side formed substantially entirely by the right side surface of the height divider plate 162 and a right side formed substantially entirely by the left side surface of an adjacent height divider plate.

As shown in FIG. 8, each width direction divider plate 162 is positioned behind the freezing plate 22 such that the included angle β between the upper surface of each width direction divider plate and the rear wall is greater than 90°. It slopes downward and forward from the barrier 154. In one or more embodiments, the included angle (β) is at least 100° and less than 180°. It can be seen that the included angle between the upper surface of each width divider plate 16 and the front plane FP is substantially equal to the included angle β. Additionally, the included angle between the bottom surface of each horizontal splitter plate 162 and the rear wall 154 (and also the included angle between the bottom surface of each horizontal splitter plate 162 and the front plane FP) is substantially 180 degrees. It can be seen that it is the same as °-β. The upper and lower portions of the peripheral wall 156 of the fan are oriented substantially parallel to the width divider plate 162 in one or more embodiments.

A series of threaded studs 168 extend outwardly from the peripheral wall 156 at spaced locations around the perimeter of the freeze plate 22. As described in more detail below, threaded studs 168 are used to secure the freeze plate 22 to the evaporator housing 170, which attaches the evaporator assembly 20 to the support 110. The studs 168 are suitably shaped and arranged to connect the freeze plate 22 to the evaporator housing 170 and to the support 110 so that the freeze plate 22 is positioned against the rear wall of the freeze plate when it is installed within the ice maker 10. (154) and the front plane (FP) is inclined forward.

VII. evaporator housing

9-14, the evaporator housing 170 will now be described in more detail. Generally, the evaporator housing 170 is configured to support the evaporator pipe 21 and the freezing plate 22. As explained in more detail below, the water distributor 25 is integrated directly within (i.e., forms a part of) the evaporator housing 170. The evaporator housing 170 includes a frame including a lower part 172, an upper part 174, and first and second side parts 176 that extend together around the perimeter of the freeze plate 22. Each of the lower part 172, top part 174, and opposing side parts 176 is, in one or more embodiments, formed from a single piece of monolithic material (e.g., molded plastic). The interior surfaces of the lower part 172, upper part 174 and opposing side parts 176 may include gaskets (not shown) to assist in watertight sealing of the evaporator housing. The upper part 174 of the evaporator housing 170 forms the lower part (broadly the first part) of the two-part distributor 25 in the illustrated embodiment.

The rear wall 178 is supported on frame parts 172, 174, 176, 178 assembled in spaced apart relationship with the rear wall 154 of the freeze plate 22. As shown in Figure 14, the evaporator housing 170 defines an enclosed space 180 between the rear wall 154 of the freeze plate 22 and the rear wall 178 of the housing. As described in U.S. Patent Application Publication No. 2018/0142932, which is hereby incorporated by reference in its entirety, in one or more embodiments, two separate layers of insulation (182, 184) fill the enclosed space (176). and completely insulate the evaporator pipe (21).

The lower part 172, upper part 174, opposing side parts 176 and/or rear wall 178 form the evaporator housing 170 in various ways, including snap fit features, bolts and nuts, etc. They may have features that facilitate assembling them together to do so. For example, each frame component 172, 174, 176 includes a stud opening 186 arranged to receive a stud 168 on a corresponding wall portion of the peripheral wall 156 of the freeze plate 22. A portion of stud hole 186 is visualized in Figure 12. In one or more embodiments, rear wall 178 is joined to assembled frame components 172, 174, and 176 by ultrasonic welding.

15 and 16, an example of how housing components 172, 174, and 176 are attached to freeze plate 72 is shown in greater detail. Specifically, top housing component 174 is shown, but it will be appreciated that other housing components may be attached to the freeze plate in a similar manner. Upper part 174 includes a front section that defines stud openings 186. In the illustrated embodiment, each stud opening 186 includes a countersunk screw recess that includes an annular shoulder 192. The upper part 174 is positioned on top of the freeze plate 22 such that one stud 168 is received within each opening 186. In the illustrated embodiment, a gasket 194 is located between the top of the freeze plate 22 and the bottom of the upper part 174 to seal the interface between the two parts. A nut 196 is tightened on each stud 168 to attach the top part 174 to the freeze plate 22. Additionally, because the housing upper part 174 forms the lower part of the dispenser 25, tightening the nut 196 on the stud also attaches the dispenser directly to the freeze plate in the illustrated embodiment. Each nut 196 is tightened against a shoulder 192 of each countersunk recess 186 (broadly, the nut is tightened directly against the upper housing part 170 or the lower distributor part). In the illustrated embodiment, cap 198 is disposed over the top of countersunk recess 186. Suitably, the top of cap 198 is substantially flush with the surface of component 174 to provide a smooth surface for water flowing through distributor 25.

VIII. Mounting the evaporator assembly so that the freeze plate is tilted forward.

Referring again to FIGS. 9 and 10 , each side component 176 of the evaporator housing 170 includes preformed lower and upper screw openings 200 and 202 at vertically spaced locations. The upper and lower screw openings 200, 202 are configured to be positioned in registration with the screw openings 130, 132 of the respective side wall portions 116, 118 of the support portion 110. When each side piece 176 is secured to the freeze plate 22 via a stud 168, the screw openings 200, 202 are in the rear wall 154 and front plane FP of the freeze plate 22. They are spaced apart along a substantially parallel oriented imaginary line IL2. 17, screws (not shown) secure the evaporator assembly 20 to the support 110 through aligned lower screw openings 130, 200 and aligned upper screw openings 132, 202. At this time, the virtual line IL2 of the evaporator housing 170 is aligned with the forward inclined virtual line IL1 of the support.

Accordingly, the screw openings 130, 132, 200, 202 position the freeze plate 22 on the support 110 such that the posterior wall 154 and anterior plane FP are aligned with the vertical axis VA and the support 110. Oriented at an anterior tilt angle (α) with respect to all of the posterior plane (BP). In one or more embodiments, the included angle α between posterior wall 154/front plane (FP) and vertical axis VA/posterior plane (BP) is at least about 1.5°. For example, in an exemplary embodiment, the included angle α is approximately 2.0°. Accordingly, the illustrated ice maker 10 is configured to mount the freezing plate 22 within the enclosure 29 such that the rear wall 154 slopes forward. Although the one-piece support 110 and side parts 176 of the evaporator housing 170 are used to mount the freeze plate 22 in an inclined orientation in the illustrated embodiment, other embodiments may be used to mount the freeze plate 22. It will be appreciated that the method may be used.

Conventional wisdom in the field of ice makers considers that orienting the freeze plate with grid-shaped divider plates such that the rear wall of the freeze plate slopes forward will adversely affect the water distribution performance of the ice maker. However, due to the high quality flow distribution produced by the water distributor 25—e.g., achieved using one or more of the water distribution features described below—the water is forced to flow in the direction where the rear wall 154 slopes forward. Even if the freezing plate 22 is mounted in this state, it is effectively distributed to the mold 150. Additionally, the inclined freeze plate 22 allows the ice maker 10 to quickly harvest ice using gravity. In one or more embodiments, the ice maker 10 is configured to perform a harvest cycle in which ice is discharged from the mold 150 of the freeze plate 22, wherein substantially the only force imparted to the ice during the harvest cycle is gravity. . For example, the harvest cycle is performed by activating the hot gas valve 24 to redirect hot refrigerant gas back into the evaporator piping 21, thereby warming the freeze plate 22. The ice in the mold 150 begins to melt and slides forward down the tilted transverse divider plate 162, away from the freeze plate, and into the ice bin 30. In a harvest cycle where substantially the only force imparted to the ice is gravity, no mechanical actuators, compressed air jets, etc. are used to force the ice away from the freeze plate 22. Rather, slightly melted ice falls from the freezing plate 22 by gravity.

IX. water dispenser

Now, with reference to FIGS. 9, 18 and 19, an exemplary embodiment of the dispenser 25 will now be described. As previously described, the distributor includes a lower part 174 that forms the upper part of the evaporator housing 170. Dispenser 25 further includes an upper part 210 that is releasably attached to lower part 174 to form a dispenser. Although the illustrated distributor 25 includes a two-piece distributor integrated directly into the evaporator housing 170, it will be appreciated that the distributor may be formed from a different number of parts in other embodiments and attached to the ice maker in other ways. You will be able to. As shown in FIG. 9 , distributor 25 is mounted on evaporator assembly 20 adjacent the top of freeze plate 22 and has a width (WF) extending generally along the width WF of freeze plate 22. WD). The distributor 25 extends widthwise from a right end adjacent the right side of the freeze plate 22 (broadly the first end) to a left end adjacent the left side of the freeze plate 22 (broadly the second end).

Distributor 25 has a rear upstream end forming an inlet 212 and a front downstream end forming an outlet 214. The downstream end extends transversely adjacent to the upper-front corner of the freezing plate 22, and the upstream end extends transversely at a location spaced rearward from the downstream end. In the illustrated embodiment, inlet 212 is formed by an opening at the upstream end of the dispenser, and outlet 214 is formed by the exposed lower front edge of dispenser 25. In use, this edge is arranged so that water flows from the edge onto the upper portion of the freeze plate 22. It is contemplated that the inlet and/or outlet may have different configurations in different embodiments.

As shown in FIG. 20 , distributor 25 defines a distributor flow path FP extending generally forward from inlet 212 to outlet 214 . Distributor 25 is positioned in a distributor flow path (FP) to discharge water from outlet 214 such that water flows from the upper portion to the lower portion of freeze plate 22 generally uniformly along the width WF of the freeze plate. ) is generally configured to direct the water delivered through the distributor along the As described in more detail below, distributor 25 includes a plurality of water distribution features that direct water flowing along flow path FP to be generally uniformly distributed along substantially the entire width of the distributor.

Before explaining how the distributor 25 is assembled and used to distribute water onto the freeze plate 22, each of the lower and upper components 174, 210 will now be described in detail.

IX.A. Distributor lower part

21 and 22, the lower distributor component 174 has a right end wall 216 (broadly, a first end wall) at the right end of the distributor 25 and a left end wall (broadly, a first end wall) at the left end of the distributor 25. 218) (broadly, the second end wall), and a lower wall 220 extending in the width direction from the right and left end walls. Referring to Figure 23, lower dispenser component 174 is attached directly to freeze plate 22, as described above. Additionally, in the illustrated embodiment, the lower distributor component 174 has insulation 184 that fills the enclosed space 180 between the rear wall 154 of the freeze plate and the rear wall 178 of the evaporator housing 170. come into direct contact with The front section 222 of the bottom wall 220 is generally positioned above the freeze plate 22 to mount the dispenser component 174 on the freeze plate as described above, and the rear section 224 of the bottom wall is generally positioned above the freeze plate 22. It is positioned above the enclosed space 180 to directly contact the insulation 184.

In the illustrated embodiment, the rear section 224 includes a rear leg 226 extending downwardly from the rear end of the lower wall and a front leg 228 extending downwardly at a location spaced forward from the rear leg. Each of the front and rear legs 226, 224 extends transversely between the right and left end walls 216, 218 of the lower distributor part 174. The rear legs 226 are sealingly engaged with the rear wall 178 of the evaporator housing 170 (e.g., the rear legs are ultrasonically welded to the rear wall). Lower wall 220 defines lower recess 230 located between front and rear legs 226, 228. Lower recess 230 extends widthwise between right and left end walls 216, 218 and forms the upper portion of enclosed space 180. Accordingly, a portion of insulation 184 is received within recess 230 and is in direct contact with the lower distributor component along the three sides forming the recess. This is taken into account as heat loss between the distributor and evaporator.

24, in the illustrated embodiment each end wall 216, 218 includes an elongated tongue 232 formed along an interior surface. Although only the left end wall 218 is shown in FIG. 24, it will be appreciated that the right end wall 216 has substantially the same mirror symmetrical tongue 232. The elongated tongue 232 extends longitudinally parallel and generally in an anteroposterior direction. Elongated tongue 232 is generally configured to form a male fitting that releasably couples lower distributor component 174 to upper distributor component 210 without the use of separate fasteners. Each elongated tongue 232 has a front end and a rear end longitudinally spaced from the front end. Between the front end and the rear end, each tongue includes a slight recess 234.

19 and 20, bottom wall 220 generally extends forward from a rear upstream end to a front downstream end. Rear wall 236 extends upwardly from the upstream end of bottom wall 220. An inlet opening 212 is formed in the rear wall 236. In the illustrated embodiment, the inlet opening 236 is centered on the back wall 236 generally at a spaced location between the end walls 216 and 218. Thus, broadly speaking, the inlet openings 212 through which water is led into the interior of the distributor 25 are spaced widthwise between the first and second ends of the distributor. In use, the distributor 25 is configured to direct water to flow along the lower wall 220 from the inlet opening 212 in a generally forward direction (FD) from the upstream end of the lower wall to the downstream end.

An integral inlet tube 238 protrudes rearwardly from the rear wall 236 and fluidly communicates therethrough through an inlet opening 212. Tube 238 tilts downward and rearward as it extends away from rear wall 236. Inlet tube 238 is configured to couple to the ice maker's water line 63 (FIG. 1). Accordingly, when ice is being made, the pump 62 pumps water from the sump 70 through the water supply line 63 and through the integral inlet tube 238 into the distributor 25. When ice is not being made, residual water in distributor 25 may drain through inlet tube 238, down water line 63 and into sump 70.

In the illustrated embodiment, rear section 224 of lower wall 220 slopes downward and rearward along substantially the entire width of the lower wall. In contrast, the front section 222 of the lower wall 220 slopes downward and forward along substantially its entire width. Accordingly, the front section 222 forms an outlet section along which water flows forward and downward toward the downstream end of the lower wall 220. Between the slanted rear section 224 and the slanted front section 222, the lower wall includes an intermediate section including a transverse groove 240. The transverse groove is configured to sealingly receive a portion of the upper distributor part 210 when the upper distributor part is coupled to the lower distributor part 174. In one or more embodiments, grooves 240 are convex in the width direction (see Figure 33). The apex of the lower wall 220 is located immediately upstream of the widthwise groove 240. The rear section 224 of the lower wall slopes downward from the apex to the rear wall 236. As shown in FIG. 23 , the posterior section 224 of the lower wall 220 includes a beveled surface 242 that forms the apex and a rearmost (or most upstream) surface portion 244 (broadly, the upstream segment). do. The slope 242 and the rearmost surface portion 244 extend widthwise from the right end wall 216 to the left end wall 218. The slope 242 slopes generally upward in the front direction and generally downward in the rear direction. The rearmost surface portion 244 slopes generally upward in a forward direction more gradually than the slope surface 242 . The rearmost surface portion 244 is oriented at an angle of less than 180° relative to the ramp surface 242 such that the rearmost surface portion is inclined generally downward in a rearward direction at a more gradual angle than the ramp surface in the illustrated embodiment.

Bottom wall 220 is configured to passively drain water from distributor 25 when ice maker 10 stops making ice. Whenever the ice maker 10 stops making ice, residual water in the front portion of the distributor 25 flows forward along the inclined front section 222 (outlet section) of the lower wall 220 and exits ( 214) onto the freezing plate 22. Similarly, the residue in the rear portion of the distributor 25 flows rearwardly along the inclined rear section 224 and drains through the inlet opening 212 into the inlet tube 238. The forwardly directed water flows downward along the freeze plate 22 and then flows from the freeze plate into the sump 70. The water guided backwards flows downwardly into the sump (70) through the water supply line (63). Accordingly, distributor 25 is configured to direct substantially all residual water into sump 70 when ice maker 10 is not making ice. Additionally, in one or more embodiments, the sump 70 is configured to drain substantially all of the water contained therein through the drain passage 78 when the ice maker 10 is not in use. As can be seen, the shape of the bottom wall 220 of the distributor 25 facilitates complete manual draining of the ice maker 10 when ice is not being made.

Referring to FIG. 21 , the lateral diverter wall 246 extends upwardly from the bottom wall 220 along the rearmost surface portion 244 . The lateral diverter wall 246 is spaced between the rear wall 236 and the slope 242. Lateral diverter wall 246 extends upwardly from bottom wall 220 to an upper edge spaced below the top of assembled distributor 25 (see Figure 20). Diverter wall 246 extends widthwise from a right end (broadly, first end) distal to right end wall 216 to a left end (broadly, second end) distal to left end wall 216. do. The lateral diverter wall 246 is located in front of the inlet opening 214. As water flows into distributor 25 through the inlet opening, lateral diverter wall 246 diverts at least a portion of the water laterally outward, forcing the water to flow around the left and right ends of the lateral diverter wall. It is configured to do so.

20A and 23, the downstream end of lower wall 220 forms a downwardly curved surface tension curve 247 extending transversely from right end wall 216 to left end wall 218. The downwardly curved surface tension curve 247 is configured such that surface tension causes water flowing along the bottom wall 220 to adhere to the curve and be guided downward by the curve toward the upper end of the freeze plate 22. In one or more embodiments, surface tension curve 270 is formed at least in part by a radius R of at least 1 mm. In certain embodiments, surface tension curve 270 is defined by a radius of less than 10 mm. In one or more embodiments, surface tension curve 270 is defined by a radius inclusively ranging from 1 mm to 3 mm. In an exemplary embodiment, surface tension curve 270 is defined by a radius of 1.5 mm.

Bottom wall 220 further includes a dripping surface 249 extending generally downward from surface tension curve 274 to a lower edge defining an outlet 214 of distributor 212. The water drop surface 249 extends in the width direction from the right end wall 216 to the left end wall 218. The falling surface 249 is generally configured such that surface tension causes the water delivered through the distributor 25 to adhere to the falling surface and flow downward along the falling surface onto the upper end of the freezing plate 22. In one or more embodiments, the falling surface 249 is angled forwardly in the ice maker 10 such that the falling surface is oriented generally parallel to the rear wall 254 (and front plane FP) of the forward angled freeze plate 22. Lose.

IX.B. upper distributor parts

25-27, the upper distributor component 210 has a right end wall 250 (broadly, a first end wall) at the right end of the distributor 25 and a left end wall (broadly, a first end wall) at the left end of the distributor 25. 252) (broadly, the second end wall). The width of the upper distributor part 210 is slightly less than the width of the lower distributor part 174 such that the upper distributor part is configured to be nested between the end walls 216, 218 of the lower distributor part.

28, in the illustrated embodiment each end wall 250, 252 includes an elongated groove 254 along its exterior surface. Although only the left end wall 252 is shown in FIG. 28, it will be appreciated that the right end wall 250 has substantially identical mirror symmetrical grooves 254. Generally, the elongated groove 254 mates with a male fitting formed by the elongated tongue 232 to releasably couple the upper distributor part 210 to the lower distributor part 174 without the use of separate fasteners. It is configured to form a complementary female fitting. The elongated grooves 254 are generally parallel and extend longitudinally generally in a front-to-back direction. The rear end of each elongate groove 254 defines an expanded opening through which each elongated tongue 174 can pass into the groove. Each end wall also forms a projection 256 that protrudes into the groove at a spaced location between the front and rear ends of the groove 254.

Referring again to FIGS. 25-27 , the upper distributor component 210 includes an upper wall 258 extending transversely from a right end wall 250 to a left end wall 252. Top wall 258 extends generally forward from the rear edge edge. Front wall 260 extends generally downward from the front end of the upper wall to the free lower edge edge. Two handle portions 262 extend forward from the front wall 260 in the illustrated embodiment.

26 and 27, the upper distributor component 210 further includes a berm 264 extending downwardly from the upper wall 258 at a spaced location between the rear edge edge and the front wall 260. Includes. The dam 264 extends transversely from the right end wall 250 to the left end wall 252 and has a free lower edge edge configured to be received within the transverse groove 240 of the lower distributor part 174. As shown in Figure 27, the lower edge edge of the dam 264 is convex in the width direction. The dam 264 forms a plurality of openings 266 at spaced apart locations along the width WD of the distributor 25. The lower portion of the dam 264 below the opening 266 is configured to hold back water until the water level reaches the lower part of the opening. Opening 266 is configured to allow water to pass through the opening when delivered through distributor 25. Adjacent openings are separated by portions of weirs 264 that are configured to form segmented weirs that allow water to intersect in spaced segments along the width WD of distributor 25 (through the openings).

IX.C. 2-Part assembly of the distributor

29 and 30, to assemble the distributor 25, the upper distributor part 210 is aligned laterally with the space between the end walls 216, 218 of the lower distributor part 174. Next, the upper part 210 is moved rearwardly into the space between the rear walls 216 and 218 such that the elongated tongue 232 of the lower part is slidably received within the elongated groove 254 of the upper part. RD).

30, the evaporator assembly 20 is suitably arranged within the ice maker enclosure 29 so that the top component 210 is installed through an access opening 268, such as a doorway in the cabinet 50. /can be removed. In the illustrated embodiment, entrance 268 is spaced from the front of evaporator assembly 20 in the forward direction (FD). Additionally, the front opening 122 of the support 110 is located between the front portion of the evaporator assembly 20 and the entrance 268. Accordingly, upper distributor component 210 may be installed by moving the component through entrance 268 and opening 122 in the rearward direction (RD). The upper distributor part 210 is removed by moving the part through the opening 122 and the entrance 268 in the forward direction (FD).

Each tongue 232 is configured to be slidably received within a respective groove 254 as the upper distributor part 210 moves toward the lower distributor part 174 in the rearward direction (RD). That is, the parallel longitudinal orientation of the tongue 232 and the groove 254 facilitates coupling the upper distributor part 210 to the lower distributor part 174 by simply moving the upper distributor part in the rearward direction (RD). Let's do it. Accordingly, the complementary fitting formed by tongue 232 and groove 254 is configured to engage by inward movement of upper distributor component 210 from doorway 268 into the interior of enclosure 29. Additionally, the complementary fittings 232 and 254 are configured to be separated by simply pressing the upper distributor component 210 away from the lower distributor component 174 and toward the entrance 268 in the forward direction (FD). When maintenance or repair of dispenser 25 is required, the technician simply opens door 52 (FIG. 2), grasps handle 262, and lowers upper dispenser component 210 through doorway 268. Pull outward in the forward direction (FD). To replace the upper dispenser part 210, the technician inserts the part through the opening 268, aligns the open end of the groove 254 with the tongue 232, and pushes the upper part rearward. Tongue 232 is then slidably received within groove 254 and a complementary fitting thereby connects upper distributor part 210 to lower distributor part (210) without using any additional fasteners such as screws or rivets. 174).

The illustrated embodiment uses the elongated tongue 232 of the lower distributor part as the male fitting and the elongated groove 254 of the upper distributor part as the complementary female fitting, but other forms or arrangements of the complementary integral fittings. This one or more embodiments may be used to releasably couple one dispenser component to another dispenser component. For example, it is expressly contemplated that in certain embodiments one or more male fittings may be formed on the upper distributor part and one or more complementary female fittings may be formed on the lower distributor part. It is also contemplated that the fitting may be formed in an alternative or additional location other than the end of the distributor.

31, each pair of complementary fittings includes a detent configured to retain each tongue 232 in an engaged position along a respective groove 254. More specifically, protrusions 256 formed in grooves 254 are configured to be received in recesses 234 of tongue 232 to provide a detent when the complementary fitting is in the engaged position. The detent resists inadvertent removal of the upper distributor part 210 from the lower distributor part 174 and provides a tactile snap when the tongue 232 is slid into the engaged position along the groove 254. It will be appreciated that the detent may be formed in different ways in one or more embodiments.

20 and 32, as the upper distributor part 210 slides in the rearward direction (RD) to join the distributor parts together, the lower edge edge of the dike 264 is positioned downstream of the lower wall 220. It slides along the front) section 222. When the upper distributor component 210 reaches the engaged position, the lower edge edge of the weir 264 is received within the groove 240. In one or more embodiments, positioning the dam 264 within the groove 240 requires pushing the upper component 210 backwards past some interference with the lower component 174. When the lower edge edge of the weir 264 is received within the groove 240, the weir sealingly engages the lower wall 220 so that water flowing along the distributor flow path FP is flush with the lower edge edge of the weir. Flow is prevented from flowing through the interface between the walls and is instead directed to flow across the embankment through the plurality of openings 266.

The dam 264 extends widthwise along the middle section of the assembled distributor 25 at a spaced location between the front wall 260 and the rear wall 236. The only joints between the upper distributor part 210 and the lower distributor part 174 in this middle section of the distributor 25 are the tongue-and-groove connections at the left and right ends of the distributor. Accordingly, in the illustrated embodiment, the middle section of the distributor 25 includes engagement portions at the first and second ends of the distributor that limit upward movement of the upper distributor part 210 relative to the lower distributor part 174, The distributor has substantially no restrictions on the upward movement of the upper distributor part relative to the lower distributor part along the middle section of the distributor in places between these joints. However, because the lower edge edge of the weir 264 is convex and the groove 240 is correspondingly concave laterally (FIG. 32), even when the distributor parts 174, 210 bend and deform during use, the weir and The seal between the lower walls 220 is maintained and water is reliably directed to flow through the openings 266 instead of downward through the interface between the dam and the lower walls.

IX.D. Water flow through distributor

Referring to Figure 20, distributor 25 allows water to flow along a flow path (FP) between the lower and upper walls (220, 258) and then along the surface tension curve (247) and drop surface (249) of the freeze plate. It is configured to direct water to flow from the inlet 212 to the outlet 214 so as to be directed downward on the upper portion of 22. Initially, water flows generally in a forward direction from the inlet tube 238 through the inlet opening 212 in the rear wall 236. The water then encounters the lateral diverter wall 246. The lateral diverter wall 246 diverts at least a portion of the water laterally outward, causing the water to continue forward through the transverse gap between the end of the lateral diverter wall and the end of the distributor 25.

After flowing past the lateral diverter wall 246, the water encounters a slope 242 and a divided weir 264. Slope 242 is immediately upstream of weir 264 such that water flowing along bottom wall 220 of distributor 25 flows upward along the slope before flowing across the weir. The berm 264 is configured such that the opening 266 is spaced above the bottom wall 220 (e.g., the lower edge of the opening is spaced above the apex of the slope 242). Accordingly, in the illustrated embodiment, water must flow upwardly along the slope 242 and along a portion of the height of the weir 264 before it can flow across the weir and through the opening 266. . In one or more embodiments, the weir 264 is at a height of the lower edge of the opening 266 before water begins to overflow through the opening and over the weir, before the portion of the distributor 25 upstream of the weir begins to overflow. and is generally configured to be recharged with water to the corresponding level. In certain embodiments, the inclined surface 242 has an opening that directs at least a portion of the water flowing in the forward direction (FD) along the inclined surface before the upstream portion of the distributor 25 is filled with water to a level corresponding to the height of the lower edge of the opening. It can be induced to flow through (266). After flowing across the weir 264, the water falls downward onto the inclined forward outflow section 222 of the lower wall 220 and then flows downward and forward.

As can be seen, the upper rear edge of the front outlet section 222 is spaced below the opening 266 a distance substantially greater than the apex of the slope 242. Accordingly, water falls a relatively large distance from the split weir 264 onto the front outlet section 222, which may create turbulence upon impact, thereby improving the distribution of water within the distributor 25. In one or more embodiments, the vertical distance between the lower edge of opening 266 and the upper rear edge of front outlet section 222 is at least 5 mm; For example at least 7 mm, for example at least 10 mm; For example, about 12 to 13 mm.

Referring to Figure 20A, in the assembled dispenser 25, the front wall 260 of the upper dispenser component 210 forms a protruding front wall that protrudes from the lower wall 220. The lower edge edge of the front wall 260 is spaced over the forward/downward angled front outflow section 222 of the lower wall 220 such that a flow restriction 270 is formed between the outflow section and the protruding front wall. Flow restriction 270 includes a gap (eg, a continuous gap) extending widthwise between the first and second ends of distributor 25 . Generally, flow restrictor 270 is configured to limit the rate at which water flows through the flow restrictor toward outlet 214. In one or more embodiments, the flow restriction 270 is less than 10 mm, such as less than 7 mm; For example, less than 5 mm; For example, it has a height extending vertically from the outflow section 222 to the bottom of the front wall 260 of about 2 to 3 mm.

Water flowing forward along the front section 222 reaches the flow restrictor 270, which inhibits or slows the flow of water. In one or more embodiments, the protruding front wall 260 acts as a type of inversion bank. Flow restrictor 270 slows the flow of water to a point where the water begins to slightly recharge the front of distributor 25. This creates a small water reservoir behind the flow restrictor 270. A metered amount of water flows continuously from this recharged reservoir through flow restriction 270 along substantially the entire width WD of distributor 25.

Surface tension curve 247 - more broadly, the downstream end of bottom wall 220 - protrudes forward of protruding front wall 260 and flow restriction 270. After the water flows (e.g., is metered) through the flow restrictor 270, it adheres to the downwardly curved surface tension curve 247 as it flows generally forward. The surface tension curve 247 directs the water downward onto the falling surface 249. The water adheres to the falling water surface 249 and flows downward along it. Finally, water is discharged from the outlet edge 214 of the dripping surface 249 onto the upper end of the freezing plate 22.

Due to water distribution features, such as one or more of the lateral diverter wall 246, slope 242, split weir 264, flow restriction 270, surface tension curve 247, and drop surface 249, water It is discharged from outlet 214 at a substantially uniform flow rate along the width WD of distributor 25. Accordingly, the distributor 25 directs the water delivered through the distributor to flow downwardly along the front of the freeze plate 22 generally uniformly along the width WF of the freeze plate during the ice making cycle. Moreover, the distributor 25 controls the dynamics of the flowing water so that it adheres to the front surface of the freeze plate 22 as it flows generally downward. Accordingly, distributor 25 allows ice to form at a generally uniform rate along the height HF and width WF of freeze plate 22.

X. Use

Referring again to Figure 1, during use the ice maker 10 alternates between an ice making cycle and a harvest cycle. During each ice making cycle, the cooling system is operated to cool the freeze plate 22. At the same time, the pump 62 delivers water from the sump 70 through the water supply line 63 and also through the distributor 25. Distributor 25 distributes water along the upper portion of freeze plate 22 to freeze into ice within mold 150 at a generally uniform rate along the height (HF) and width (WF) of freeze plate 22. distribute. When the ice reaches a thickness suitable for harvesting, pump 62 is turned off and hot gas valve 24 redirects hot refrigerant gas into evaporator piping 21. The hot gas warms the freezing plate 22, causing the ice to melt. The melting ice falls by gravity from the forward-inclined freezing plate 22 into the bin 30. When harvest is complete, pump 62 can be reactivated to start a new de-icing cycle. However, if no additional ice is required, drain valve 510 is opened. The remaining water in the distributor 25 is drained into the sump 70 as described above, and the water from the sump is drained through the drain passage 78. Drain valve 510 may close when water level sensor 64 detects that sump 70 is empty. If repair or maintenance of the dispenser 25 is even required, the technician can simply open the door 52 to the enclosure and withdraw the upper component 210 as described above. No fasteners are used when removing and replacing the upper distributor component 210.

XI. Ice level detection

Referring now to FIGS. 33 and 34 , the illustrated ice maker 10 includes an ice level sensor 310 configured to detect the level of ice in the bin 30 while the ice maker is in use. Various uses for ice level detection are or may be known to those skilled in the art. For example, it is known to turn off an ice maker when an ice level sensor indicates that the ice bucket is full of ice.

In one or more embodiments, ice level sensor 310 includes a time-of-flight sensor. Typically, a suitable time-of-flight sensor 310 will include a sensor board 312 (e.g., a printed circuit board) that includes a light source 314, a photon detector 316, and an embedded control and measurement processor 318. It may be possible. An example time-of-flight sensor board is It is sold by STMicroelectronics, Inc. under the name: Certain non-limiting examples of time-of-flight sensors within the scope of this disclosure are described in US Patent Application Publication No. 2017/0351336, which is hereby incorporated by reference in its entirety. Broadly speaking, light source 314 is configured to emit optical pulses toward a target at a first time. Photon detector 316 is configured to detect target reflected photons of the optical pulse signal returning to time-of-flight sensor 310 at a second time. Control and measurement processor 318 is configured to instruct the light source to emit optical pulses and determine a period of time (time of flight) between the first time and the second time. In one or more embodiments, the control and measurement processor 318 is further configured to determine the distance between the time-of-flight sensor and the target, based on the determined period of time, and cause the sensor board 312 to output a signal representing the determined distance. . In certain embodiments, ice maker controller 80 is configured to receive measurement signals from sensor board 312 and use the measurement signals to control the ice maker.

In the illustrated embodiment, the target for time-of-flight sensor 310 is the top surface within the interior of ice bucket 30. That is, the time-of-flight sensor 310 is configured to direct the optical pulse toward the bottom of the ice bucket 30 through the bottom of the ice maker 10. The optical pulse will be reflected from the bottom of the ice bin 30 if ice is not present, or from the top of the ice contained within the bin if ice is present. Based on the duration (time of flight) of the photon(s), control and measurement processor 318 determines the distance the photon(s) have traveled, which determines the level of ice present within bin 30 (broadly, quantity or quantity) - for example, the distance determined is inversely proportional to the amount of ice in the bin. The time-of-flight sensor 310 can provide a quick and highly accurate indication of the level of ice in the bin. Moreover, compared to conventional ice level detection systems utilizing capacitive, ultrasonic, infrared, or mechanical sensors, time-of-flight sensor 310 provides significantly greater measurement accuracy and responsiveness under the typical dark and irregularly shaped conditions of ice buckets. It was found to provide.

34-37, in one or more embodiments, the one-piece support 110 is configured and arranged for integrating a time-of-flight sensor. For example, in the illustrated embodiment, the bottom wall 112 of the support 110 has a sensor aperture 320 through which the time-of-flight sensor 310 is configured to emit optical pulses and receive reflected photon(s). form In one or more embodiments, sensor opening 320 is located on the rear side of vertical support wall 114. Suitably, sensor opening 320 extends from its upper surface through its lower surface and through the entire thickness of lower wall 112. Accordingly, sensor opening 320 is defined by an inner peripheral surface 322 of bottom wall 112 extending circumferentially around the sensor opening and extending height along the thickness of the bottom wall. In the illustrated embodiment, the perimeter of sensor opening 320 is generally circular; Other shaped sensor apertures may be used in one or more embodiments.

In the illustrated embodiment, the vertically extending support wall 114 of the support 110 includes an integrally formed sensor mount 324 (FIG. 36) configured to mount a time-of-flight sensor 310 on the support. The illustrated sensor mounting portion 324 includes a pair of integrated connection points 326 formed on the side wall portion 116 of the vertically extending support wall 114. In one or more embodiments, each connection point 326 includes an integral screw hole. In the illustrated embodiment, each connection point 326 includes a boss that protrudes laterally outwardly from a major side surface of the side wall portion 116 and a screw hole formed in the boss. Time-of-flight sensor 310 includes a mounting bracket 330 configured to couple to vertically extending support wall 114 through screw holes. As described in more detail below, mounting bracket 330 allows light source 314 to broadcast optical pulses through sensor opening 320 toward the bottom of ice bucket 30 and photon detector 316. A time-of-flight sensor board 312 is mounted so that photons reflected from the ice bucket can be detected through the sensor aperture.

As will be apparent to those skilled in the art from the description of the vertically extending support wall 114 provided in Section V above, the vertically extending support wall may separate the food safe side of the ice maker 10 from the non-food safe side. . In the illustrated embodiment, the sensor opening 320 is located on the non-food safe side of the ice maker 10 (e.g., rear of the vertically extending support wall 114), which allows the time-of-flight sensor 310 to As it falls on the outside of the wall of ice, it can be mounted on the ice maker on the non-food safe side. Drain passages and certain electrical and cooling system components are also located on the non-food safe side of ice maker 10 in one or more embodiments. In contrast, the ice drop opening 123 and ice forming device 20 allow the ice produced by the ice maker 10 and harvested into the bin 30 to be stored in non-food safety equipment on the non-food safe side. It is located on the food safety side to ensure that it is never contaminated by food.

To prevent contamination of the food safety side of the ice maker 10 and ice bucket 30 via the sensor opening 320, the illustrated time-of-flight sensor 310 is installed on the lower portion of the support 110 to seal the sensor opening. It is sealedly engaged with the wall 112. More specifically, the illustrated time-of-flight sensor 310 includes a sensor enclosure 332 and a gasket 334 sealingly compressed between the sensor enclosure and bottom wall 112.

In the illustrated embodiment, enclosure 332 includes a base component 336 and a cover portion 338 of a mounting bracket 330 that is releasably fastened to the base component via removable fasteners, for example screws. do. The base part 336 forms the lower wall of the enclosure 332, and the cover portion 338 of the mounting bracket 330 forms the upper wall of the enclosure. In one or more embodiments, cover portion 338 is connected to base piece 336 to form an interior chamber 340 (FIG. 37) between the cover portion and the base piece. Time-of-flight sensor board 312 is operably received in interior chamber 340 of enclosure 332. In one or more embodiments, the inner chamber 340 may be environmentally sealed to protect the time-of-flight sensor board 312 housed in the inner chamber. For example, a compressible gasket (not shown) can be compressed between the base part and the cover part to seal the interface therebetween.

In the illustrated embodiment, the bottom wall of sensor enclosure 332 defines a window opening 342. A window pane 344 is mounted on the bottom wall across the window opening 342. Suitably, the window pane 344 is transparent to the optical pulses emitted by the light source 314 of the time-of-flight sensor board 312 and thus also to the photons reflected from the ice and/or ice bucket to the photon detector 316 ( ) are transparent.

37, in the illustrated embodiment, window opening 342 is formed by an annular window frame 346 formed on the bottom wall. The window frame includes an inner annular protrusion 348 that protrudes upwardly from the lower wall and an outer annular protrusion 350 that protrudes downwardly from the lower wall. The inner annular protrusion 348 forms an annular shoulder 352 that supports the window pane 344. Suitably, the window pane sealingly engages the annular shoulder 352 such that the pane seals the window opening 342. In one or more embodiments, the seal between the window pane 344 and the window frame 346 is created by an adhesive (not shown) that bonds the pane to the window frame. In certain embodiments, the window pane may be fastened to a window frame such that the pane compresses an annular gasket (not shown) against an annular shoulder to form a seal between the window pane and the window frame. It will be clear that providing a seal between the window pane 322 and the bottom wall of the base part 336 enables the sensor enclosure to seal the sensor opening 320.

33, the base component 336 of the sensor enclosure 332 includes an integrated board mount configured to mount the sensor board 312 within the interior chamber 340 at a precise vertical clearance distance (VSD) from the window pane 344. 354). For example, the illustrated board mount 354 may be configured to mount the board 312 such that the light source 314 is vertically spaced from the top surface of the window pane 344 by a clearance distance (VSD) greater than 0.0 mm and less than 0.5 mm. It is composed. The magnitude of the vertical separation distance (VSD) is exaggerated in the schematic diagram of Figure 33 to better illustrate the relationship between the parts. However, Figure 37 shows the relative positions of the window pane 344 and the sensor board 312 to scale.

Any suitable board mounting device for securely mounting the board at a desired clearance distance (VSD) may be used without departing from the scope of the present disclosure. 38 , in one or more embodiments, the board mount 354 includes at least one integral mounting boss 356 (broadly speaking) extending upwardly from the bottom wall of the base 336 and/or downwardly from the top wall of the cover. may include at least one or a plurality of integrated connection points). In the illustrated embodiment, board mount 354 includes three spaced apart mounting bosses 356 extending upwardly from the bottom wall of base component 336. Suitably, each mounting boss 356 has a removable fastener 357 (e.g., It is configured to receive a thread forming fastener, such as a screw. It can be seen that the mounting boss 336 has a specified height in relation to the height of the window frame shoulder 352, which ensures that the sensor board 312 is mounted at the proper clearance distance (VSD). (In one or more embodiments, base part 336 may be an injection molded plastic part manufactured to very tight tolerances to ensure proper clearance distance (VSD)).

37, the gasket 334 is generally shaped (e.g., an inverted top hat shape) corresponding to the lower portion of the sensor enclosure 332 and the lower wall 112 of the support 110. has For example, the illustrated gasket 334 includes a tube section 360 configured to extend circumferentially around the outer annular protrusion 350 of the window frame 346. Tube section 360 has a vertical tube axis (VTA) and extends from the bottom to the top along the vertical tube axis. The inner peripheral surface of the tube section 360 is configured to engage congruently with the outer perimeter of the outer annular projection 350 about its entire circumference. The outer peripheral surface of the tube section 360 is configured to conformally engage with the inner peripheral surface 322 of the lower wall 112 of the ice maker support 110 about its entire circumference. In one or more embodiments, the tube section 360 is radially compressed (about the vertical tube axis (VTA)) between the outer peripheral surface of the outer annular protrusion 350 and the inner peripheral surface 322 of the lower wall 112. about).

The illustrated gasket 334 further includes a flange section 362 extending radially outward from the top of the tube section 360. The upper surface of the flange section 362 is in conformally engaged with the lower surface of the lower wall of the base component 336, and the lower surface of the flange section 362 is in conformal engagement with the upper surface of the lower wall 112 adjacent the sensor opening 320. It fits into the surface in a congruent manner. The flange section 362 is compressed axially (about the vertical tube axis (VTA)) between the lower wall of the base part 336 and the lower wall 112 of the support 110. The illustrated ice maker 10 utilizes a time-of-flight sensor gasket 334 having an inverted top hat shape to seal the sensor opening 310 through which the time-of-flight sensor 310 operates, but uses a time-of-flight sensor gasket 334 to seal the sensor opening. It will be understood that configurations are possible without departing from the scope of the present disclosure.

34 , in the illustrated embodiment, the mounting bracket 330 axially aligns the flange section 362 with the lower wall of the base component 336 relative to the lower wall 112 of the ice maker support 110. Sensor enclosure 332 is supported in compression (about the vertical tube axis (VTA)). The mounting bracket 330 includes a generally vertical front-to-back extending mounting flange portion 372 configured to extend along the side wall portion 116 of the vertically extending support wall 114 proximate the sensor mounting portion 324. Mounting flange portion 372 has first and second screw holes 374 through which each removable fastener extends and extends vertically for mounting a mounting bracket on vertically extending support wall 114. It is configured to be releasably attached to the connection point 326 of the support wall 114. Generally, a vertical, laterally extending connecting web portion 376 extends along the rear wall portion 120 of the vertically extending support wall 114 at a transverse (e.g., vertical) angle relative to the mounting flange. Generally, a horizontal cover portion 338 is connected to the lower end of the connecting web portion 376 and extends rearward therefrom over the top of the base component 336. As described above, the base component is fastened to the cover portion 338 to form the sensor enclosure 332.

In addition to providing highly accurate measurements of ice level under multiple conditions, the illustrated time-of-flight sensor 310 also advantageously allows periodic servicing of the time-of-flight sensor to maintain ice level measurement accuracy over the life of the ice maker. facilitates. In one exemplary method of servicing the ice maker 10, the access panel of the cabinet 29 is removed to provide access to the time-of-flight sensor 310. Subsequently, the removable fastener connecting the mounting bracket 330 to the connection point 326 is removed (eg, unscrewed). Next, the user may remove the time-of-flight sensor 310 as a unit from the ice maker 10. For example, in one or more embodiments, a user lifts enclosure 332 and mounting bracket 330 together to remove sensor 310 from sensor opening 320. In some cases, gasket 334 may be removed along with enclosure 332; In other cases, the gasket may remain within opening 320. In either case, after removing the removable fastener from connection point 326, time-of-flight sensor 310 is separated from bottom wall 112 of ice maker 10 to expose sensor opening 320.

When time-of-flight sensor 310 is removed, a user can perform various service or maintenance tasks. For example, in one or more embodiments, a user may access time-of-flight sensor 310 to update software or firmware of the time-of-flight sensor, retrieve stored data from the time-of-flight sensor, or perform other control or data processing tasks. You can also connect a processor. In an exemplary embodiment, the user cleans the exterior surface of the window pane 344 when the time-of-flight sensor 310 is removed from the ice maker. Cleaning the window pane 344 involves removing debris and scale (e.g., mineral deposits) that may have formed on the pane during use of the ice maker. It may be important to maintain a clean windowpane to ensure long-term accuracy of the time-of-flight sensor 310. For example, debris and scale may obscure the transparency of the pane 344 to photons used in time-of-flight measurements. Accordingly, periodic removal of debris and scale ensures that time-of-flight sensor 310 functions consistently as intended.

After the window pane 344 is cleaned and/or other time-of-flight sensor service tasks are performed, the sensor 310 may be reinstalled as a unit. Sensor enclosure 332 and bracket 330 are positioned as a unit to cover sensor opening 320. Additionally, repositioning the sensor 310 within the ice maker 10 properly re-establishes the seal between the enclosure 332 and the bottom wall 112 of the support 110. For example, time-of-flight sensor 310 is repositioned such that gasket 334 is compressed between bottom wall 112 and enclosure 332. After repositioning the time-of-flight sensor, a removable fastener is inserted through hole 374 in mounting bracket 330 and secured to connection point 326 of vertical support wall 114.

If the time-of-flight sensor 310 becomes inoperative, a new time-of-flight sensor unit can also be installed in the same manner as described above with the existing unit being reinstalled.

Accordingly, it can be seen that the support portion 110 and the time-of-flight sensor 310 are configured to facilitate periodic removal of the time-of-flight sensor from the ice maker 10. Periodic removal allows the time-of-flight sensor 310 to be maintained, updated and/or replaced as needed to preserve the accuracy of ice level sensing measurements. Moreover, the ice maker 10 facilitates removal and reinstallation/replacement of the time-of-flight sensor 310 in this manner ensuring that the seal on the food-safe side of the ice maker is preserved when the time-of-flight sensor is placed in the operating position. Let's do it. Moreover, because the time-of-flight sensor 310 is mounted on the non-food safe side of the ice maker 10, it remains unobstructed and does not interfere with ice harvesting during use.

XII. gravity drain

Ice maker manufacturers typically design and manufacture ice makers so that a pump discharges water from the ice maker sump. For example, the same pump that recirculates water from a sump through a distributor may also optionally be coupled to a discharge passage through which water can be pumped to drain the sump (e.g., via a discharge valve). The drain pump, when mounted above the sump, operates to discharge drain water through a passage above or at the level of the sump. In contrast, gravity drains require the drain passage to be located below the sump. This consideration leads manufacturers to use active drain pumps instead of passive gravity drains.

A manual gravity drain passage must be located beneath the sump to function. However, in commercial ice makers, it is not possible to open the drain passage through the bottom of the ice maker cabinet because it must be possible for the bottom to be supported directly on top of the ice bucket or dispenser unit. Accordingly, commercial (flat bottom) ice makers with manual gravity drains must accommodate a drain passage (i) located below the sump and (ii) capable of directing water from the sump to an outlet located on the side of the ice maker. This requires mounting the sump in an elevated position above the bottom of the ice maker to provide the necessary vertical clearance for a suitable drain passage.

However, a typical commercial ice maker has an industry standard total height of approximately 22 inches. In order for gravity drain to function, the ice maker must be installed within a 22-inch height, from top to bottom, having the following members: (a) water distributor, (b) freeze plate below the water distributor, (c) below the freeze plate. The sump, and (d) the drain passage below the sump, shall be accommodated. Therefore, it can be seen that using a gravity drain instead of a pump discharge system limits the available height for the freeze plate. Moreover, ice makers have typically considered any reduction in freezing plate size undesirable on the assumption that it would cause the ice maker to produce ice less efficiently. As such, ice maker manufacturers have not utilized gravity drains in standard height commercial ice makers.

However, the inventors have recognized that it is impossible for the pump discharge mechanism to remove all water from the sump. The inventors also recognized that residual water is prone to stagnation when the ice maker is not making ice. Moreover, stagnation can lead to the formation of bacteria or other harmful biological agents.

Accordingly, with reference to FIG. 39, the present inventors have achieved the goal of producing ice without substantially reducing the size of the freezing plate 22 or substantially reducing the ice production rate of the ice maker compared to a conventional commercial ice maker with an active discharge pump. A total height (H0) of approximately 22 inches (height from top to bottom of ice maker cabinet 29) including a gravity drain and a number of complementary features that facilitate accommodating the gravity drain within the standard height of the maker. An ice maker 10 having was considered. Although these complementary features are described in relation to the standard height ice maker 10, it will be appreciated that ice makers of other heights may utilize one or more of the features without departing from the scope of the present disclosure.

As previously described, the freeze plate 22 has a height HF along its rear wall 154. The illustrated evaporator assembly 20 also has a height H1 defined by a spacer in the illustrated embodiment extending from the top of the freeze plate to the bottom of the evaporator assembly below the bottom of the freeze plate 22. Includes spacer 450. Accordingly, in an embodiment, the bottom of the freeze plate 22 is spaced vertically above the bottom of the evaporator assembly 20. This is because the required ice production rate for the illustrated ice maker 10 is less than what the ice maker can achieve within its existing footprint if the freezing plate extends along the entire height H1. Because the application for the illustrated ice maker 10 requires less ice production, the illustrated ice maker is configured to produce the required amount of ice with relatively high energy efficiency. A person of ordinary skill in the art will know that, for manufacturing efficiency, an ice maker manufacturer will produce multiple models of ice makers with essentially the same water system and cabinet, but with different sized cooling system components to meet different levels of ice production needs. It will be appreciated that different heights of freeze plates may be used.

39A, another embodiment of an ice maker 10' is shown that is configured to produce ice at a faster rate. Compared to ice maker 10, ice maker 10' has the same cabinet size and has an evaporator assembly 20' with the same height H1 extending from the top of the freeze plate to the bottom of the evaporator assembly. Ice maker 10' differs from ice maker 10 only in that ice maker 10' includes a cooling system and a freezing plate 22' configured to produce ice at a faster rate. Accordingly, the ice maker 10' includes an evaporator assembly 20' including a higher freeze plate 22' and no lower spacer. Freeze plate 22' has a height (HF') extending substantially to the bottom of evaporator assembly 20'. Accordingly, in Figure 39A, the freeze plate height HF' is only slightly less than height H1.

39 and 39A , the evaporator assemblies 20, 20' have approximately the same height H1 and extend from the bottom of the evaporator assemblies 20, 20' to the bottom of the ice maker 10, 10'. have approximately the same height (H3). In one or more embodiments, the height H1 is in a generic range of about 9 inches to about 16 inches (e.g., about 10 inches to about 15 inches, about 11 inches to about 15 inches, about 12 inches to about 13 inches). It is in In certain embodiments, the height H3 is greater than 4 inches (eg, greater than 5 inches, greater than 6 inches). In one or more embodiments, the height H3 is about 4 inches to about 11 inches (e.g., about 4 inches to about 10 inches, about 5 inches to about 9 inches, e.g., about 6 inches to about 8 inches). ) is in the comprehensive range of. A person skilled in the art will recognize that this range of heights (H1) is approximately equivalent to the range of corresponding heights used in conventional ice makers that discharge ice water through a pump, but that the height (H3) is similar to that of conventional pump discharge ice makers. You will understand that it is larger than the corresponding height range. This, combined with the additional feature of maximizing the available space for the drain passageway 78, facilitates the use of gravity drain within the standard height cabinet 29 of the ice maker.

In one or more embodiments within the scope of the present disclosure, it can be seen that the height of the ice maker enclosure (H0) is less than 24 inches and the height of the evaporator assembly (H1) is greater than 10 inches. For example, in certain embodiments, the height of the enclosure (H0) is less than 23 inches and the height of the evaporator assembly (H1) is greater than 11 inches. In an exemplary embodiment, the enclosure height (H0) is approximately 22 inches and the evaporator assembly height (H1) is at least 12 inches.

One feature that enables the use of gravity drainage has already been described at length above: the integration of a water distributor 25 into the top of the evaporator assembly 20. This does not directly affect the height of the freezing plate 22, but reduces the overall height of the sub-assembly of the water distributor 25 and evaporator 21 compared to the corresponding sub-assembly of a conventional ice maker. Therefore, instead of the reduction in height achieved by reducing the height of the freeze plate 22, the reduction in height reduces the height H2 of the ice forming device 20 between the top of the freeze plate and the top of the distributor 25. This is achieved by reducing For example, in one or more embodiments, the height H2 is less than or equal to 5 inches (e.g., less than or equal to about 4 inches, less than or equal to 3 inches, or less than or equal to about 2.5 inches). Accordingly, integration of the distributor 25 into the evaporator assembly 20 allows the freeze plate 22 to be mounted closer to the top of the ice maker 10, which in turn allows freezing from the bottom of the ice maker 10. It provides greater height (H3) to the bottom of the plate (22).

Another feature that accommodates gravity drainage is the one-piece support 110. As previously mentioned, the support 110 is only one piece of material, i.e. the distributor 25, the freeze plate 22 and the sump at precisely defined vertically spaced locations with respect to the vertically extending support wall 114. (60) is firmly supported. No vertical space is consumed by the stacked parts since all major components are supported on parts of the same material forming the vertically extending walls 114. Additionally, as described above, in one or more embodiments, support 110 is formed in a very precise compression molding process. Accordingly, the tolerance for changes in the vertical position of each component supported on wall 114 may be very small in one or more embodiments.

As described above, in certain embodiments, the bottom of the freeze plate 22 is spaced from the bottom of the enclosure by a height H3 of less than 12 inches (e.g., less than 11 inches in height, less than 10 inches in height). . Accordingly, the space allowed for the sump 60 and gravity drain in the illustrated embodiment is still somewhat limited. Additional features of the drain passage 78 that make it possible to fit within limited available heights will now be described. As explained in more detail below, the illustrated support 110 also supports the drain passage 78 at a precise height and the drain passage 78 is located directly adjacent to the bottom of the ice maker 10. It is configured to enable opening through an outlet opening 410 on the rear side (broadly on the side wall). Moreover, as will also be described in detail below, the inventors have considered a novel, robust ice maker drain valve 512 that allows for reliable gravity draining and requires only a very small height between its inlet and outlet ends.

40-42, in the illustrated embodiment, drain passage 78 extends rearwardly from drain opening 414 (FIG. 41) at the bottom of sump 60 through vertically extending support wall 114. and an extending first upstream tube section 412 (FIG. 42). The sump 60 is configured such that all water within the sump drains by gravity through the drain opening 414 when the drain passage 78 is open. For example, the bottom of the sump 60 may form a basin that directs water to flow by gravity into the drain opening 414.

Referring to Figure 42, the vertically extending support wall 114 defines a spaced drain passage opening 416 below the lower portion of the sump. The first tube section 412 has its upstream end connected to the drain opening 414 through the drain passage opening 416 and across the vertically extending support wall 114 (e.g., across the rear wall portion 120). It extends posteriorly from the adjacent part of. Accordingly, in the illustrated embodiment the upstream end of the first tube section 412 is located on the food safe side of the ice maker 10 and the downstream end of the first tube section is located on the non-food safe side of the ice maker. Suitably, a vertically extending support wall 114 and a first tube section are formed at the opening 416 to prevent contaminants from the non-food safe side of the ice maker 10 from passing through the drain passage opening to the food safe side. A seal is formed between the outside of 412). For example, a gasket (not shown) may be disposed around the first tube section 412 at the interface between the first tube section and the vertically extending support wall 114.

42, in the illustrated embodiment, the center of the drain passage opening 416 is spaced from the bottom of the ice maker 10 by a height H4. In one or more embodiments, the height H4 is in a generic range of about 0.5 inches to about 4 inches (e.g., about 0.5 inches to about 3 inches, about 0.5 inches to about 2 inches, about 0.5 inches to about 1.5 inches). It is in The drain passage opening 416 can be seen spaced below the sump mount 128 (described above, see Figure 5). In one or more embodiments, the center of the drain passage opening 416 is spaced below the bottom of the sump 60 by a height H5. Suitably, the height H5 is in the inclusive range of about 1.0 inches to about 4.0 inches (e.g., about 1.5 inches to about 3.0 inches, about 2 inches to about 2.5 inches). Drain passage opening 416 has a cross-sectional dimension CD1 (e.g., a diameter) in the inclusive range of about 0.5 inches to about 2.0 inches (e.g., about 0.5 inches to about 1.5 inches, about 0.5 inches to about 1.0 inches). ) may also have. Accordingly, the height H4' between the bottom of the drain passage opening 416 and the bottom of the ice maker 10 ranges from about 0.5 inches to about 4 inches (e.g., from about 0.5 inches to about 2.5 inches, from about 0.5 inches to about 1.5 inches, about 0.5 inches to about 1.0 inches), and the height H5' between the bottom of the drain passage opening and the bottom of the sump 60 can be in the inclusive range of about 1.5 inches to about 4.5 inches (e.g. For example, about 2.0 inches to about 3.5 inches, about 2.5 inches to about 3.0 inches).

40 and 41 , in the illustrated embodiment, the second tube section 420 of the drain passageway 78 located on the non-food safe side of the ice maker 10 is rear of the rear wall portion 120. extends laterally along the side and connects the downstream end of the first tube section to a drain valve 512 (described in more detail below). The third tube section 422 of the drain passage 78 is a fourth downstream tube section of the drain passage 78 laterally rearwardly along the full width of the second tube section 520 from the outlet of the drain valve 512 ( 424). The support wall 114 has an integral drain valve mount (e.g., a screw hole and (i.e. integrally formed connection points). Accordingly, the sump mounting portion and the drain valve mounting portion are configured to mount the sump 60 and drain valve 512 on the support portion 110 on opposite sides of the at least one vertically extending support wall 114 . The fourth tube section 424 has an upstream inner end connected to the downstream end of the third tube section, through the rear wall of the cabinet 29 and terminating at a drain coupling 426 at a drain opening 410 (FIG. 39). It has a downstream outer end. 39-42 and 46, the insulation around each tube section 412, 420, 422, 424 is omitted to provide a clearer view of other features. Additionally, throughout the drawing, insulating panels are omitted to provide a clearer view of other components.

43 and 44 , in one or more embodiments within the scope of the present disclosure, drain valve 512 includes a valve body, generally indicated at 514, and a valve member, generally indicated at 516. . The valve member is moveable relative to the valve body 514 between an open position (Figure 3) and a closed position (Figure 4). The illustrated valve 512 further includes a valve positioner 518 (broadly an actuator) configured to selectively move the valve member 516 between an open and closed position. In one or more embodiments, valve positioner 518 is coupled to a controller 80 (FIG. 1) that controls the operation of valve 512 using the valve positioner. In the illustrated embodiment, valve positioner 518 includes a linear actuator configured to move valve member 516 along axis VVA between an open and closed position. For example, the positioner 518 is configured to move the valve member 516 along the axis VVA in the open direction (OD) toward the open position, and the positioner is configured to move the valve member 516 along the axis (VVA) in the closed direction (CD) toward the closed position. It is configured to move the valve member accordingly. In the open position (FIG. 3), the valve member 516 allows water to flow from the first and second tube sections 412, 420 (broadly, the upstream end of the drain passage 78) through the valve body into the third and third tube sections. 4 positioned relative to the valve body 514 to allow flow into the tube sections 422, 424 (broadly, the downstream end of the drain passage). In the closed position (FIG. 4), the valve member 516 engages the valve body 514 to allow water to flow through the valve 110 from the second tube section 420 of the drain passage 78 to the third tube section 422. (broadly, from the upstream end to the downstream end). In the illustrated embodiment, spring 519 is operably connected to valve member 516 to bias the valve member in the closing direction (CD) toward the closed position.

The valve body 514 forms a valve passage 520 that is fluidly coupled between the upstream and downstream ends of the drain passage 78. In the illustrated embodiment, valve body 514 includes an inlet tube 522 and an outlet tube 524 extending transversely to axis VVA. Inlet tube 522 forms an upstream section of valve passageway 520 and is configured to fluidly couple valve 512 to the upstream end of drain passageway 78 . Outlet tube 524 forms a downstream section of valve passageway 520 and is configured to fluidly couple valve 512 to the downstream end of drain passageway 78 . The illustrated valve body 516 further includes an outer cylindrical chamber 526 and an inner cylindrical chamber 528 extending longitudinally generally along axis VVA. The inner chamber 528 is located within the outer chamber 526 and is fluidly connected to the upstream end of the outlet tube 524. The outer chamber 526 extends circumferentially away from and around the inner chamber 528 and is fluidly coupled to the downstream end of the inlet tube 522 .

Inlet tube 522 has a central axis (ITA), an inner radius (ITR), and a lower edge 522A at its outlet end, eg, an opening through which the inlet tube opens into cylindrical chamber 528. Lower edge 522A is spaced apart from central axis ITA by radius ITR. Similarly, outlet tube 524 has a central axis (OTA), a radius (OTR), and a lower edge 524A at its outlet end. The lower edge 524A is likewise spaced apart from the central axis OTA by the radius OTR. In the illustrated embodiment, upstream lower edge 522A is spaced above downstream lower edge 524A by a height H6. Accordingly, when valve 512 is open, water from sump 60 may flow from inlet tube 522 through valve passage 520 and fill external chamber 526. Water within the outer chamber 526 flows over the upper edge of the inner chamber 526 and then flows out of the valve 512 through the outlet tube 524. In one or more embodiments, the height H6 is in the inclusive range of about 0.1 inches to about 0.3 inches (eg, about 0.15 inches to about 0.25 inches, for example, about 0.2 inches). In the illustrated embodiment, the radii (ITR, OTR) are substantially the same. Accordingly, the central axes (ITA, OTA) are spaced apart by a height H6' in the inclusive range of about 0.1 inch to about 0.3 inch (e.g., about 0.15 inch to about 0.25 inch, e.g., about 0.2 inch). there is. A person skilled in the art will recognize that the heights H6, H6' are less than the corresponding heights in conventional discharge valves. The relatively short heights H6, H6' minimize the required height of the drain passageway 78, thereby partially enabling the use of a manual gravity drain in a standard height ice maker 10 without compromising the ice production rate of the ice maker. . It will be appreciated that the drain valve may have a valve body of other configuration in one or more embodiments without departing from the scope of the present disclosure.

In the illustrated embodiment, the free (upper) end of the inner chamber 528 forms an annular valve seat 530. Valve seat 530 is oriented radially inward and extends longitudinally along axis VVA. Valve seat 530 has a dimension (e.g., height) L1 (FIG. 3) extending along axis VVA. In one or more embodiments, the dimension L1 of the annular valve seat 530 is in the generic range of about 1 mm to about 10 mm, such as about 1.5 mm to about 5 mm, such as about 3 mm. Suitably, the valve seat 530 tapers radially inwardly as it extends along the axis VVA (eg, as it extends along the axis in the closure direction CD). The illustrated valve seat 530 is tapered radially inwardly along substantially the entire dimension L1 of the valve seat. In one or more embodiments, valve seat 530 is a substantially conical surface centered about axis VVA. The illustrated valve seat 530 has a cone angle α. In one or more embodiments, the cone angle α of valve seat 530 is in the generic range of about 30° to about 70°, for example about 45°.

Valve member 516 is generally configured to sealingly engage valve seat 530 in the closed position (FIG. 4) to prevent water in outer chamber 526 from flowing into inner chamber 528. Closing valve 512 thereby blocks flow through valve passage 520 from the upstream end of drain passage 78 to the downstream end. Accordingly, valve member 516 is configured to close drain passage 78 and retain water within sump 60 when the valve member is in the closed position. Suitably, the valve member 516 may be formed at least in part from an elastically deformable material that is elastically compressed against the valve seat 530 when the valve member is in the closed position.

In the illustrated embodiment, valve member 516 includes an annular sealing surface 532 extending longitudinally along axis VVA. The annular sealing surface 532 is configured to radially overlap and sealingly engage the valve seat 530 along axis VVA when the valve member 516 is in the closed position. In other words, valve seat 530 and sealing surface 532 are configured to engage one another at a sealing interface extending longitudinally along axis VVA in the closed position of valve 512 . Seal engagement between sealing surface 532 and valve seat 530 closes the valve.

Suitably, the sealing surface 532 has a shape that substantially corresponds to the shape of the valve seat 530 (e.g., the valve seat and the sealing surface have substantially the same shape but include surface portions oriented in opposite directions). ). Accordingly, the illustrated sealing surface 532 has a dimension L2 (FIG. 43) that is oriented radially outward and extends along axis VVA. In one or more embodiments, the dimension L2 of sealing surface 532 is in the generic range of about 1 mm to about 10 mm, such as about 3 mm to about 7 mm, such as about 5 mm. In one or more embodiments, dimension L2 is about 1 mm larger than dimension L1. Suitably, the sealing surface 532 tapers radially inwardly as it extends along the axis VVA (eg, as it extends along the axis in the closure direction CD). The illustrated sealing surface 532 tapers radially inwardly along substantially the entire dimension L2 of the sealing surface. In one or more embodiments, sealing surface 532 is a substantially conical surface centered about axis VVA. The illustrated sealing surface 532 has a cone angle β suitably substantially equal to the cone angle α of the valve seat 530 . Accordingly, in one or more embodiments, the cone angle β of the valve member sealing surface 532 is in the generic range of about 30° to about 70°.

In the illustrated embodiment, annular sealing surface 532 is configured to radially overlap and sealingly engage valve seat 530 along a substantially conical sealing interface extending adjacently along axis VVA. In certain embodiments, in the closed position, sealing surface 532 and valve seat 530 have a length along axis VVA approximately equal to dimension L1, for example between about 1 mm and about 10 mm, for example They are configured to engage each other at adjacent seal interfaces having a length along the axis in the generic range of about 1.5 mm to about 5 mm, for example about 3 mm. For example, sealing surface 532 and valve seat 530 may be configured to engage one another along substantially the entire dimension L2 of the conical sealing surface. In certain embodiments, sealing surface 532 and valve seat 530 may be configured to engage one another along substantially the entire dimension L1 of the conical valve seat. In the illustrated embodiment, the fluid seal between valve body 514 and valve member 516 is formed solely by surfaces 530 and 532 extending longitudinally along axis VVA. However, it will be appreciated that in one or more embodiments a portion of the sealing interface may be formed by a surface extending in a radial plane. For example, valve member 516 may be modified to include a flange having a downwardly facing surface extending in a radial plane that sealingly engages an upwardly pointing edge of valve seat 530 extending in a radial plane. It is considered to be Additionally, although the valve seat 530 and valve member seal surface 532 are substantially conical in the illustrated embodiment, one or both of the surfaces may have other annular shapes in one or more embodiments.

During use, the controller 80 instructs the valve positioner 518 to open and close the drain valve 512 by moving the valve member 516 relative to the valve body 514 in the opening and closing directions (OD, CD). At the same time, the spring 519 biases the valve member 516 in the closing direction CD. Therefore, positioner 518 must overcome the force of the spring to open valve 512.

The valve member 516 and valve seat 530 often come into contact with hard water during operation, so scale can form on both the valve seat and the valve member sealing surface 532. Compared to drain valves in conventional ice makers that have a flat sealing surface forming a planar sealing interface, drain valve 512 has been found to perform better in high scale environments. While scale build-up on the flat sealing surfaces of a conventional ice maker can quickly cause an ineffective seal, drain valves 512 can develop scale on the valve seat 530 and sealing surfaces 532 over time. It has been shown to maintain its seal even as it accumulates.

Valve 512 was tested with a number of conventional valves in which the sealing surface between the valve member and the valve body extends in a plane perpendicular to the valve axis. Specifically, ice makers equipped with each type of valve were operated with very hard water with dissolved solids exceeding 650 ppm. Ice makers with traditional valves failed after approximately 250 to 300 hours of operation, at which point the conventional valves had a leak rate of 2 to 5 cc/sec through the planar interface between the valve member and the valve body. In comparison, the ice maker equipped with valve 512 was operated for over 1250 hours before a minimum leak rate of 0.5 cc/sec was observed.

In addition to more robust operation in hard water environments, valve 512 is also more energy efficient than conventional discharge valves. One reason for this is that less spring pressure is required to maintain a fluid seal between valve body 514 and valve member 516. As a result, less energy is required of the positioner 518 to open the valve 512 against the force of the spring 519. In one or more embodiments, valve 512 is configured such that positioner 518 uses less than 8.5 Watts (e.g., inclusively in the range of about 7.5 Watts to about 8.2 Watts) to open the valve. In contrast, conventional discharge valves require more than 9.0 watts to open the valve because greater spring pressure is required to maintain the valve seal in the closed position.

45-47, the illustrated ice maker support 110 is configured to minimize the height of the drain passage 78 thereby minimizing the height at which the sump 60 is mounted above the bottom of the ice maker 10. It further includes a drainage passage groove 610. Drain passage groove 610 extends longitudinally from a front end (broadly inner end) adjacent the exterior of ice maker 10 to a rear end (broadly outer end). As shown in FIG. 47, the drain passage groove 610 has a lower portion, and the lower portion of the drain passage groove at the rear end is vertically spaced below the lower portion of the drain passage groove at the front end by a height H7. In one or more embodiments, the height H7 is at least 0.25 inches, such as in the inclusive range of about 0.25 inches to about 0.75 inches, such as in the inclusive range of about 0.35 inches to about 0.55 inches or about 0.4 inches to about 0.5 inches. there is. Accordingly, the lower portion of the drain passage groove 610 slopes downward as the drain passage groove extends from the front end to the rear end. For example, drain passage groove 610 may have an inclusive range of about 1° to about 10° (e.g., an inclusive range of about 1° to about 5°, an inclusive range of about 2° to about 4°, e.g. It can be tilted downward with a tilt angle (δ) of about 3°). In certain embodiments, the bottom of the drain passage groove 610 at its rear (outer) end is less than 1.0 inches, such as 0.9 inches, from the bottom of the bottom wall 112 forming the bottom of the ice maker 10. They are spaced apart by a height H8 of less than, less than 0.75 inches, or inclusively from about 0.05 inches to about 0.1 inches (e.g., inclusively from about 0.1 inches to about 0.75 inches).

46, the drain passage groove allows the drain coupling 426 to be positioned very low on the exterior vertical wall (in this case, the rear wall) of the ice maker cabinet 29. In the illustrated embodiment, the fourth drain tube section 424 is configured to drain water received in the drain passageway groove 610 such that the drain tube is tilted downward as it extends from adjacent the front end of the groove 610 to the rear end. Includes tube. Much like the drain passage through groove 610, in one or more embodiments, the axis (DTA) of the drain tube(s) comprising the fourth drain tube section 424 ranges comprehensively from about 1° to about 10°. It is tilted downward and backward at a tilt angle δ that is in the inclusive range of about 1° to about 5°, inclusive of about 2° to about 4°, for example about 3°. Additionally, the lower portion of the inner periphery of the fourth drain tube section 424 at its front end is at least 0.25 inches, for example about 0.25 inches to about 0.75 inches, above the lower portion of the inner periphery of the fourth drain tube section 424 at its rear end. and are spaced apart by a height H9 in the inclusive range of, for example, about 0.35 inches to about 0.55 inches or about 0.4 inches to about 0.5 inches. Moreover, the lower portion of the inner circumference of the fourth drain tube section 424 at its rear end, which forms the lower portion of the downstream end of the drain passageway 78, is less than 1.2 inches, e.g., less than 1.1 inches, less than 1.0 inches, or spaced above the bottom of the ice maker 10 by a height H10 generally ranging from about 0.2 inches to about 1.2 inches.

Accordingly, it can be seen that the illustrated standard height ice maker 10 includes a gravity drain but does not reduce the ice production capacity of the ice maker relative to a corresponding conventional ice maker that discharges water via a pump. In the illustrated embodiment, this feat includes, among other things, (i) integrating the evaporator 20 and distributor 25, and (ii) the main construction of the ice maker 10 on a single monolithic support wall 110. mount the element, (iii) configure the drain valve 512 to require only a small height H6 between its inlet 522 and outlet 522, (iv) open immediately adjacent the bottom of the ice maker ( This is achieved by forming an inclined groove 610 in the bottom wall 112 of the ice maker to allow the drain tube 624 to be opened through 410. Ice makers within the scope of the present disclosure may include none, all, any one, or any combination of more than one of features (i) through (iv) without departing from the scope of the present disclosure.

Gravity draining is contemplated to improve certain aspects of the performance of the ice maker 10 compared to conventional ice makers with discharge pumps. For example, it is known to periodically drain some or all of the water from the ice maker sump to prevent the ice water from developing high concentrations of dissolved solids. Typically, this operation occurs during or immediately before the harvest cycle. However, even after the discharge valve is opened, running the pump essentially causes some of the water already present in the water supply passage to be delivered through the water distributor onto the freeze plate. During the harvest cycle, this is undesirable because warmer water flows along the ice being harvested, which may cause premature melting of the ice. The venting operation can also be performed before harvesting begins, but doing so prolongs the duration of the freezing cycle, resulting in inefficient operation of the ice maker. In contrast, in the exemplary method of using the illustrated ice maker to drain water from the sump 60, the controller 80 opens the drain valve 24 after the controller opens the hot gas valve 24 to initiate the harvest cycle. Open (512). Opening the drain valve 512 allows the water in the sump to drain by gravity but does not cause any flow through the distributor 25 or transfer any additional water onto the freeze plate 22. Accordingly, the discharge operation can be performed without introducing inefficiencies or adversely affecting ice quality. Depending on the configuration and application of the ice maker, the draining operation may periodically drain a predefined amount of water from the sump 60 by gravity (e.g., by holding the drain valve open for a predefined period of time). and/or drain all water from the sump by gravity (e.g., open the drain valve until a signal is received from the pressure sensor 82 indicating that the sump is empty before closing the drain valve). by keeping it open).

When introducing elements of the invention or preferred embodiment(s) thereof, the singular terms are intended to mean that more than one element is present. The terms “comprising,” “comprising,” and “having” are intended to be inclusive and mean that additional elements other than those listed may be present.

In light of the above, it will be seen that many of the objectives of the present invention have been achieved and other advantageous results have been obtained.

Since various changes may be made to the products and methods without departing from the scope of the invention, all matters contained in the above description are intended to be construed as illustrative and not limiting.

Claims (40)

It is an ice maker,
an enclosure having a lower part;
An evaporator assembly supported within an enclosure, the evaporator assembly comprising an evaporator and a freeze plate forming a plurality of molds where the evaporator assembly is configured to form a piece of ice, the evaporator assembly having a lower portion;
a distributor configured to distribute water delivered through the distributor onto the freezing plate such that the water is formed into ice on the freezing plate;
a sump supported within the enclosure below the freeze plate and configured to collect water flowing from the bottom of the freeze plate;
a pump configured to pump water within the sump through a distributor; and
a drain valve supported within the enclosure, the drain valve comprising a drain valve configured to selectively open and drain all water from the sump by gravity;
An ice maker wherein the bottom of the evaporator assembly is spaced from the bottom of the enclosure by a height of less than 12 inches. The ice maker of claim 1, wherein the bottom of the evaporator assembly is spaced from the bottom of the enclosure by a height of less than 11 inches. The ice maker of claim 1 , wherein the bottom of the evaporator assembly is spaced from the bottom of the enclosure by a height of less than 10 inches. 2. The method of claim 1, wherein the drain valve includes an inlet tube having an inlet tube pivot axis and an outlet tube having an outlet tube pivot axis, the inlet tube pivot axis being offset by an outlet tube pivot axis by a height in the inclusive range of about 0.1 inches to about 0.3 inches. Ice maker, spaced vertically upward. 5. The ice maker of claim 4, wherein the inlet tube pivot axis is spaced vertically above the outlet tube pivot axis by less than 0.25 inches. The ice maker of claim 1 , further comprising a support portion at the bottom of the enclosure including a lower wall and at least one vertically extending support wall extending upwardly from the lower wall. 7. The ice maker of claim 6, wherein the bottom wall includes a drain passageway groove extending longitudinally from the inner end to the outer end adjacent the exterior of the enclosure. 8. The ice maker of claim 7, wherein the outer end is vertically spaced below the inner end. 9. The ice maker of claim 8, further comprising a drain tube received within the drain passageway groove and angled downwardly as it extends from adjacent the inner end to the outer end. 7. The method of claim 6, wherein the at least one vertically extending support wall includes a sump mount configured to mount the sump on a support within the enclosure, and the at least one vertically extending support wall further includes a drain passage opening spaced below the sump mount. Including, ice maker. 11. The ice maker of claim 10, wherein the drain passage opening is spaced below the bottom of the sump. 12. The method of claim 11, wherein the at least one vertically extending support wall further comprises a drain valve mount configured to mount a drain valve on a support within the enclosure, wherein the sump mount and the drain valve mount are located on opposite sides of the at least one vertically extending support wall. An ice maker configured to mount a sump and a drain valve on a support portion of the ice maker. According to paragraph 1,
The drain valve includes a valve body defining a valve passage, the valve body comprising an annular valve seat extending longitudinally along an axis and oriented radially inwardly with respect to the axis;
A drain valve is positioned between an open position, in which the valve member is positioned relative to the valve body to allow water to flow through the valve passage, and a closed position, in which the valve member engages the valve body to block flow through the valve passage. further comprising a valve member movable relative to;
The valve member includes an annular sealing surface extending longitudinally along the axis, the annular sealing surface being configured to radially overlap and sealingly engage the valve seat along the axis when the valve member is in the closed position. It is an ice maker,
an enclosure having a bottom, a top, and a height extending from the bottom to the top;
An evaporator assembly supported within an enclosure, the evaporator assembly comprising an evaporator and a freeze plate forming a plurality of molds in which the evaporator assembly is configured to form a piece of ice, the evaporator assembly having a lower portion and the freeze plate having an upper portion; The evaporator assembly includes: an evaporator assembly having a height extending from the bottom of the evaporator assembly to the top of the freeze plate;
a distributor supported within an enclosure adjacent the top of the freeze plate, the distributor configured to distribute water delivered through the distributor onto the freeze plate such that the water forms into ice in the mold;
a sump supported within the enclosure below the freeze plate and configured to collect water flowing from the bottom of the freeze plate;
a pump configured to pump water within the sump through a distributor; and
a drain valve supported within the enclosure, the drain valve comprising a drain valve configured to selectively open and drain all water from the sump by gravity;
An ice maker, wherein the enclosure has a height of less than 24 inches and a height extending from the bottom of the evaporator assembly to the top of the freeze plate is greater than 10 inches. 15. The ice maker of claim 14, wherein the height of the enclosure is less than 23 inches and the height extending from the bottom of the evaporator assembly to the top of the freezer is greater than 11 inches. 15. The ice maker of claim 14, wherein the enclosure has a height of about 22 inches and a height extending from the bottom of the evaporator assembly to the top of the freeze plate is at least 12 inches. It is an ice maker,
a lower wall, the lower wall having a drainage passage groove formed in the upper surface of the lower wall;
an ice forming device supported on the bottom wall;
a water reservoir for holding water used by the ice forming device, the water reservoir supported on a bottom wall;
a drain valve supported on the wall, the drain valve configured to be selectively opened to drain all water from the water reservoir by gravity; and
An ice maker comprising a drain tube supported on a bottom wall and at least partially received within a drain passage groove. 18. The ice maker of claim 17, wherein the drain passage groove extends longitudinally from the inner end to the outer end adjacent the exterior of the ice maker. 19. The ice maker of claim 18, wherein the outer end is vertically spaced below the inner end. 20. The ice maker of claim 19, wherein the drain tube slopes downward as it extends longitudinally from the upstream end adjacent the inner end to the downstream end adjacent the outer end. 21. The ice maker of claim 20, further comprising an external fluid coupling connected to the downstream end of the drain tube. It is an ice maker for forming ice,
a cooling system including an ice forming device;
A water system for supplying water to an ice forming device, the water system comprising:
a water reservoir configured to retain water to form ice;
a drainage passage fluidly coupled to the water storage tank so that water in the water storage tank can drain through the drainage passage, the drainage passage having an upstream end and a downstream end; and
It includes a drain valve for selectively opening and closing the drain passage;
The drain valve includes a valve body defining a fluidly coupled valve passage between an upstream end and a downstream end of the drain passage, the valve body extending longitudinally along an axis and an annular valve seat oriented radially inwardly with respect to the axis. Includes;
The drain valve has an open position in which the valve member is positioned relative to the valve body to allow water to flow through the valve passage from the upstream end to the downstream end of the drain passage, and an open position in which the valve member is positioned relative to the valve body to allow water to flow through the valve passage from the upstream end to the downstream end of the drain passage. further comprising a valve member movable relative to the valve body between a closed position engaged with the valve body to block flow therethrough;
The valve member includes an annular sealing surface extending longitudinally along the axis, the annular sealing surface being configured to radially overlap and sealingly engage the valve seat along the axis when the valve member is in the closed position. 23. The method of claim 22, wherein the annular sealing surface has a length extending along the axis of at least 1 mm, and the annular sealing surface is configured to sealingly engage the valve seat along substantially its entire length when the valve member is in the closed position. , ice maker. 24. The ice maker of claim 23, wherein the sealing surface tapers radially inwardly as it extends along the axis. 25. The ice maker of claim 24, wherein the valve seat tapers radially inwardly as it extends along the axis. 26. The ice maker of claim 25, wherein the valve member is movable along an axis from an open position to a closed position in the closing direction, and each of the sealing surface and the valve seat is radially inwardly tapered as it extends along the axis in the closing direction. 23. The ice maker of claim 22, wherein the sealing surface is a substantially conical surface. 28. The ice maker of claim 27, wherein the valve seat has a substantially conical surface. 29. The ice maker of claim 28, wherein the valve seat and the sealing surface each have a cone angle, and the cone angles of the valve seat and the sealing surface are substantially equal. 28. The ice maker of claim 27, wherein the sealing surface has a cone angle in the inclusive range of about 30° to about 70°. 23. The ice maker of claim 22, wherein the valve seat and seal surface include surface portions having substantially the same shape but oriented in opposite directions. 23. The ice maker of claim 22, wherein the open and closed positions of the valve member are spaced apart along the axis. 23. The ice maker of claim 22, wherein the valve member is axially spaced from the valve seat when the valve member is in the open position. 23. The ice maker of claim 22, wherein the sealing surface and the valve seat sealingly engage each other at an annular sealing interface extending along the axis when the drain valve is closed. 35. The ice maker of claim 34, wherein the sealing interface has a length extending along the axis and is at least about 1 mm in length. 35. The ice maker of claim 34, wherein the sealing interface is substantially conical. 34. The valve body of claim 33, wherein the valve body has an inlet tube and an outlet tube extending transversely to the axis, an outer chamber extending along the axis and fluidly coupled to the inlet tube, and an outer chamber extending along the axis within the outer chamber and fluidly coupled to the outlet tube. An ice maker, comprising an interior chamber coupled thereto. 38. The ice maker of claim 37, wherein the inner chamber opens into the outer chamber and has a free end forming a valve seat. 38. The ice maker of claim 37, wherein the valve passageway comprises a first segment in the inlet tube, a second segment between the outer and inner chambers, a third segment in the inner chamber, and a fourth segment in the outlet tube. 40. The ice maker of claim 39, wherein the valve is configured to sequentially flow through the first, second, third and fourth segments as water flows downstream through the valve passage.

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